motor nissan hr16de

EM-1

ENGINE

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SECTION EM A

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CONTENTS

ENGINE MECHANICAL

HR16DE

PRECAUTION ............................................... 3

PRECAUTIONS ................................................... 3Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-SIONER" ...................................................................3Precaution for Procedure without Cowl Top Cover ......3Draining Engine Coolant ...........................................3Disconnecting Fuel Piping .........................................3Removal and Disassembly ........................................4Inspection, Repair and Replacement ........................4Assembly and Installation .........................................4Parts Requiring Angle Tightening .............................4Precaution for Liquid Gasket .....................................4

PREPARATION ............................................ 6

PREPARATION ................................................... 6Special Service Tools ................................................6Commercial Service Tools ........................................7

BASIC INSPECTION ...................................10

CAMSHAFT VALVE CLEARANCE ...................10Inspection and Adjustment ......................................10

COMPRESSION PRESSURE ............................13Inspection ................................................................13

SYMPTOM DIAGNOSIS ..............................14

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................14

NVH troubleshooting Chart .....................................14

PERIODIC MAINTENANCE .........................16

DRIVE BELT .......................................................16Exploded View ........................................................16Removal and Installation .........................................16

Inspection ................................................................17Adjustment ...............................................................18

AIR CLEANER FILTER .....................................19Exploded View .........................................................19Removal and Installation .........................................19

SPARK PLUG ...................................................21Exploded View .........................................................21Removal and Installation .........................................21

REMOVAL AND INSTALLATION ...............23

DRIVE BELT IDLER PULLEY ..........................23Exploded View .........................................................23Removal and Installation .........................................23

AIR CLEANER AND AIR DUCT .......................25Exploded View .........................................................25Removal and Installation .........................................25

INTAKE MANIFOLD .........................................27Exploded View .........................................................27Removal and Installation .........................................27

EXHAUST MANIFOLD ......................................30Exploded View .........................................................30Removal and Installation .........................................30

OIL PAN (LOWER) ...........................................33Exploded View .........................................................33Removal and Installation .........................................33

FUEL INJECTOR AND FUEL TUBE ................37Exploded View .........................................................37Removal and Installation .........................................37

IGNITION COIL, SPARK PLUG AND ROCK-ER COVER ........................................................44

Exploded View .........................................................44Removal and Installation .........................................44

TIMING CHAIN ..................................................47

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EM-2

Exploded View ........................................................ 47Removal and Installation ........................................ 47

CAMSHAFT ....................................................... 56Exploded View ........................................................ 56Removal and Installation ........................................ 56Inspection ............................................................... 65

OIL SEAL ........................................................... 70

VALVE OIL SEAL ..................................................... 70VALVE OIL SEAL : Removal and Installation ......... 70

FRONT OIL SEAL ..................................................... 70FRONT OIL SEAL : Removal and Installation ........ 71

REAR OIL SEAL ....................................................... 71REAR OIL SEAL : Removal and Installation .......... 71

CYLINDER HEAD .............................................. 73Exploded View ........................................................ 73Removal and Installation ........................................ 74Disassembly and Assembly .................................... 75Inspection ............................................................... 76

UNIT REMOVAL AND INSTALLATION ..... 82

ENGINE ASSEMBLY ......................................... 82Exploded View ........................................................ 82Removal and Installation ........................................ 82

UNIT DISASSEMBLY AND ASSEMBLY .... 86

ENGINE STAND SETTING ................................ 86Setting .................................................................... 86

ENGINE UNIT .................................................... 88Disassembly ............................................................ 88Assembly ................................................................ 88

OIL PAN (UPPER) AND OIL STRAINER .......... 89Exploded View ........................................................ 89Removal and Installation ......................................... 89

CYLINDER BLOCK ........................................... 94Exploded View ........................................................ 94Disassembly and Assembly .................................... 95Inspection .............................................................. 103

HOW TO SELECT PISTON AND BEARING ...112Description ............................................................ 112Connecting Rod Bearing ....................................... 112Main Bearing ........................................................ 114

SERVICE DATA AND SPECIFICATIONS (SDS) .........................................................117

SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................117

General Specification ............................................ 117Drive Belt .............................................................. 117Spark Plug ............................................................ 118Exhaust Manifold .................................................. 118Camshaft ............................................................... 118Cylinder head ........................................................ 120Cylinder Block ....................................................... 122Main Bearing ......................................................... 125Connecting Rod Bearing ....................................... 126



PRECAUTIONS

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PRECAUTIONPRECAUTIONSPrecaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" INFOID:0000000007732304

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used alongwith a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certaintypes of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRSsystem uses the seat belt switches to determine the front air bag deployment, and may only deploy one frontair bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.Information necessary to service the system safely is included in the SR and SB section of this Service Man-ual.WARNING:• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision which would result in air bag inflation, all maintenance must be performed byan authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personalinjury caused by unintentional activation of the system. For removal of Spiral Cable and Air BagModule, see the SR section.

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-ness connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERSWARNING:• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-

tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with ahammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causingserious injury.

• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect thebattery, and wait at least 3 minutes before performing any service.

Precaution for Procedure without Cowl Top Cover INFOID:0000000007575573

When performing the procedure after removing cowl top cover, coverthe lower end of windshield with urethane, etc.

Draining Engine Coolant INFOID:0000000007575576

Drain engine coolant and engine oil when the engine is cooled.

Disconnecting Fuel Piping INFOID:0000000007575577

• Before starting work, check no fire or spark producing items are in the work area. • Release fuel pressure before disconnecting and disassembly.• After disconnecting pipes, plug openings to stop fuel leakage.

PIIB3706J



EM-4

< PRECAUTION > [HR16DE]PRECAUTIONS

Removal and Disassembly INFOID:0000000007575578

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-structed operations.

• Use care to avoid damage to mating or sliding surfaces.• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,

check that dowel pins are installed in the original position.• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.• When loosening nuts and bolts, start with the one furthest outside, then the one diagonally opposite, and so

on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Inspection, Repair and Replacement INFOID:0000000007575579

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, andreplace if necessary.

Assembly and Installation INFOID:0000000007575580

• Use torque wrench to tighten bolts or nuts to specification.• Tighten nuts and bolts in order exactly as specified in the procedure. If a tightening order or procedure is not

specified, tighten nuts and bolts equally in several different steps. Start with the nuts or bolts in the centerand then tighten diagonally starting with the inside and moving to the outside in a spiral pattern.

• Replace with new gasket, packing, oil seal or O-ring.• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for

restrictions and blockages. • Avoid damaging sliding or mating surfaces. Before assembling, completely remove foreign materials such

as cloth lint or dust, and oil the sliding surfaces. • After refilling engine coolant, bleed the air from the cooling system.• After repairing, start the engine and increase engine speed to check for engine coolant leaks, fuel leaks,

engine oil leaks, and exhaust gas leaks.

Parts Requiring Angle Tightening INFOID:0000000007575581

• For the final tightening of the following engine parts use Tool:

- Camshaft sprocket (INT) bolt- Cylinder head bolts- Main bearing cap bolts- Connecting rod cap bolts- Crankshaft pulley bolt (Note an angle wrench is required as bolt flange is provided with notches for angle

tightening)• Do not use a torque value for final tightening. • The torque value for these parts are for a preliminary step.• Ensure thread and seat surfaces are clean and coated with engine oil.

Precaution for Liquid Gasket INFOID:0000000007732305

REMOVAL OF LIQUID GASKET SEALANT• After removing the bolts and nuts, separate the mating surface and

remove the old liquid gasket sealant using Tool.

CAUTION:Do not damage mating surfaces.

• Tap the seal cutter to insert it (1).• In areas where the Tool is difficult to use, lightly tap to slide it (2).

Tool number : KV10112100 (BT-8653-A)

Tool number : KV10111100 (J-37228)

WBIA0566E



PRECAUTIONS

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LIQUID GASKET APPLICATION PROCEDURE1. Remove the old liquid gasket adhering to the gasket application

surface and the mating surface using suitable tool.• Remove the liquid gasket completely from the groove of the

liquid gasket application surface, bolts, and bolt holes.2. Thoroughly clean the mating surfaces and remove adhering

moisture, grease and foreign material.

3. Attach the liquid gasket tube to the suitable tool.Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-15, "Recommended Chemical Products and Sealants".

4. Apply the liquid gasket without breaks to the specified locationwith the specified dimensions.

• If there is a groove for the liquid gasket application, apply theliquid gasket to the groove.

• Normally apply the liquid gasket on the inside edge of the boltholes. Also apply to the outside edge of the bolt holes whenspecified in the procedure.

• Within five minutes of liquid gasket application, install the mat-ing component.

• If the liquid gasket protrudes, wipe it off immediately.• Do not retighten after the installation.• Wait 30 minutes or more after installation before refilling the

engine with oil or coolant.CAUTION:Carefully follow all of the warnings, cautions, notes, and procedures contained in this manual.

PBIC0003E

WBIA0567E

SEM159F



EM-6

< PREPARATION > [HR16DE]PREPARATION

PREPARATIONPREPARATIONSpecial Service Tools INFOID:0000000007732317

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool name

Description

KV10111100(J-37228)Seal cutter

Removing oil pan (lower and upper) etc.

KV10116200(J-26336-B)Valve spring compressor1. KV10115900(J-26336-20)Attachment2. KV10109220( — )Adapter

Disassembling and assembling valve mecha-nismPart (1) is a component of KV10116200, but Part (2) is not so.

KV10112100(BT-8653-A)Angle wrench

Tightening bolts for main bearing cap, cylinder head, etc.

KV10117100( — )Heated oxygen sensor wrench

Loosening or tightening heated oxygen sen-sor 1For 22 mm (0.87 in) width hexagon nut

KV10107902(J-38959)Valve oil seal puller

Removing valve oil seal

KV10115600(J-38958)Valve oil seal drift

Installing valve oil sealUse side A.a: 20 (0.79) dia. d: 8 (0.31) dia.b: 13 (0.51) dia. e: 10.7 (0.421)c: 10.3 (0.406) dia. f: 5 (0.20) Unit: mm (in)

S-NT046

PBIC1650E

S-NT014

NT379

NT011

S-NT603



PREPARATION

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Commercial Service Tools INFOID:0000000007732318

EM03470000(J-8037)Piston ring compressor

Installing piston assembly into cylinder bore

ST16610001(J-23907)Pulley puller

Removing pilot converter

KV11103000( — )Pulley puller

Removing crankshaft pulley

KV11105210(J-44716)Stopper plate

Holding drive plate and flywheel static

Tool number(Kent-Moore No.)Tool name

Description

S-NT044

S-NT045

NT676

ZZA0009D

Tool name Description

Power tool Loosening nuts, screws and bolts

Quick connector release Removing fuel tube quick connectors in en-gine room

PIIB1407E

PBIC0198E



EM-8

< PREPARATION > [HR16DE]PREPARATION

Spark plug wrench Removing and installing spark pluga: 14 mm (0.55 in)

Pulley holder Crankshaft pulley removing and installing

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring

Valve guide drift Removing and installing valve guide

Valve guide reamer (1): Reaming valve guide inner hole(2): Reaming hole for oversize valve guide

(J-43897-18)(J-43897-12)Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new air fuel ratio sensor (Use with anti-seize lubricant shown below.)A: [18 mm (0.71 in) dia.] for zirconia heated oxygen sensorB: [12 mm (0.47 in) dia.] for titania heated oxygen sensorC: Mating surface shave cylinderD: Flutes


JPBIA0399ZZ

NT035

S-NT048

S-NT030

PBIC4012E

PBIC4013E

JPBIA0238ZZ



PREPARATION

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Acoustic tension gauge Checking drive belt tension

Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specifica-tion MIL-A-907)

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

Manual lift table caddy Removing and installing engine

1. Compression gauge2. Adapter

Checking compression pressure

WS39930000( — )Tube presser

Pressing the tube of liquid gasket


PBIC3881E

AEM489

ZZA1210D

ZZA0008D

S-NT052



EM-10

< BASIC INSPECTION > [HR16DE]CAMSHAFT VALVE CLEARANCE

BASIC INSPECTIONCAMSHAFT VALVE CLEARANCEInspection and Adjustment INFOID:0000000007575585

INSPECTIONPerform inspection as follows after removal, replacement or installation of camshaft or valve-related parts, or ifthere are unusual engine conditions regarding valve clearance. 1. Remove rocker cover. Refer to EM-44, "Removal and Installation".2. Measure the valve clearance with the following procedure:a. Set No. 1 cylinder at TDC of its compression stroke.

• Rotate crankshaft pulley (2) clockwise and align TDC mark (nopaint) (A) to timing indicator (1) on front cover.

• At the same time, check that both intake and exhaust camlobes of No. 1 cylinder face inside ( ) as shown in the figure.

• If the lobes do not face inside, rotate the crankshaft pulley 360degrees to align as shown in the figure.

b. Use a feeler gauge (A) to measure the clearance between thevalve lifter and camshaft.

B : White paint mark (Not used for service)

PBIC3673E

1 : Camshaft (INT)2 : Camshaft (EXH)

: Engine front

JPBIA4738ZZ

Valve clearance : Refer to EM-118, "Camshaft".

JPBIA4116ZZ



CAMSHAFT VALVE CLEARANCE

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• Refer to the figure. Using a feeler gauge, measure the valveclearances at locations marked “×” in the table below (alsoshown with black arrow ( ) in the figure).

c. Set No. 4 cylinder at TDC of its compression stroke.• Rotate crankshaft pulley (2) one revolution (360 degrees) and

align TDC mark (no paint) (A) to timing indicator (1) on frontcover.

• Refer to the figure. Using a feeler gauge, measure the valveclearances at locations marked “×” in the table below (alsoshown with black arrow ( ) in the figure).

3. If out of the specifications, adjust as necessary. Refer to “ADJUSTMENT”.

ADJUSTMENTNOTE:Proper valve clearance is obtained by selecting the correct valve lifter head thickness.1. Remove camshaft. Refer to EM-56, "Exploded View".2. Remove valve lifters from the locations that are out of specification.

A : No. 1 cylinderB : No. 2 cylinderC : No. 3 cylinderD : No. 4 cylinder

JPBIA4117ZZ

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.

No. 1 cylinder at compression TDCEXH × ×

INT × ×

B : White paint mark (Not use for service)

PBIC3673E

A : No. 1 cylinderB : No. 2 cylinderC : No. 3 cylinderD : No. 4 cylinder

JPBIA4118ZZ

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.

No. 4 cylinder at compression TDCEXH × ×

INT × ×



EM-12

< BASIC INSPECTION > [HR16DE]CAMSHAFT VALVE CLEARANCE

3. Measure the center thickness of the removed valve lifters with amicrometer (A).

4. Use the equation below to calculate valve lifter thickness for replacement.

• Thickness of new valve lifter (B) can be identified by stampmark (A) on the under side of the lifter.NOTE:Available thickness of valve lifter: 26 sizes range 3.00 to 3.50mm (0.1181 to 0.1378 in) in increments of 0.02 mm (0.0008 in)when manufactured at factory. Refer to EM-118, "Camshaft".

• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.

5. Install the correct thickness valve lifter.6. Install camshaft. Refer to EM-56, "Exploded View".7. Install timing chain and related parts. Refer to EM-47, "Exploded View".8. Manually rotate crankshaft pulley a few rotations. 9. Check that valve clearances are within specification. Refer to “INSPECTION”.10. Install remaining parts in the reverse order of removal.11. Warm up the engine, and check for unusual noise and vibration.

PBIC3195J

Valve lifter thickness calculation: t = t1 + (C1 – C2)t = Valve lifter thickness to be replacedt1 = Removed valve lifter thicknessC1 = Measured valve clearanceC2 = Standard valve clearance:

Intake : 0.30 mm (0.012 in)Exhaust : 0.33 mm (0.013 in)

PBIC3196J



COMPRESSION PRESSURE

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COMPRESSION PRESSUREInspection INFOID:0000000007575586

1. Warm up engine and then turn it off. 2. Release fuel pressure. Refer to EC-126, "Work Procedure". 3. Remove ignition coil and spark plug from each cylinder. Refer to EM-44, "Exploded View".4. Connect engine tachometer (not required in use of CONSULT).5. Install compression gauge (B) with an adapter (A) (commercial

service tool) onto spark plug hole.

• Use an adapter with a diameter (a) smaller than 20 mm (0.79in). Otherwise, it may be caught by cylinder head duringremoval.

6. With accelerator pedal fully depressed, turn ignition switch to START for cranking. When the gaugepointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check eachcylinder.

CAUTION:Always use a fully charged battery to obtain the specified engine speed.• If the engine speed is out of the specified range, check the battery. Check the engine speed again with a

fully charged battery. • If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug

hole to recheck the compression.- If the added engine oil improves the compression, the piston rings may be worn or damaged. Check the

piston rings and replace if necessary.- If the compression pressure remains low despite the addition of engine oil, the valves may be malfunc-

tioning. Check the valves for damage. Replace the valve or valve seat as necessary.• If two adjacent cylinders have respectively low compression pressure and their compression remains

low even after the addition of engine oil the head gasket may be leaking, or valves in adjacent cylindersmay be damaged. Inspect and repair as required.

• If the compression pressure is below the minimum value, check the valve clearances and parts associ-ated with the combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head,cylinder head gasket). After repairing, measure the compression pressure again.

7. After inspection is completed, install removed parts.8. Start the engine, and ensure that the engine runs smoothly.9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-111, "Work Flow".

JPBIA4119ZZ

a : Less than 20 mm (0.79 in)

JPBIA0171ZZ

Compression pressure : Refer to EM-117, "General Specification".



EM-14

< SYMPTOM DIAGNOSIS > [HR16DE]NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

SYMPTOM DIAGNOSISNOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGNVH troubleshooting Chart INFOID:0000000007575587

1. Locate the area where noise occurs.2. Confirm the type of noise.3. Specify the operating condition of engine.

JPBIA4739GB



NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

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4. Check specified noise source.If necessary, repair or replace these parts.

A: Closely related B: Related C: Sometimes related —: Not related

Location of noise

Type of noise

Operating condition of engineSource of

noise Check item Refer-ence page

Before warm-

up

After warm-

up

When start-ing

When idling

When racing

While driving

Top of en-gine rock-er covercylinder head

Ticking or clicking C A — A B — Tappet

noise Valve clearance EM-10

Rattle C A — A B CCamshaft bearing noise

Camshaft journal oil clearanceCamshaft runout

EM-118

Crank-shaft pul-leycylinder block (side of engine)oil pan

Slap or knock — A — B B — Piston pin

noise

Piston to piston pin oil clearanceConnecting rod bushing oil clearance

EM-122

Slap or rap A — — B B A Piston

slap noise

Piston to cylinder bore clearancePiston ring side clear-ancePiston ring end gapConnecting rod bend and torsion

EM-122

Knock A B C B B B

Connect-ing rod bearing noise

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

EM-122EM-126

Knock A B — A B C Main bear-ing noise

Main bearing oil clear-anceCrankshaft runout

EM-125EM-122

Front of enginefront cover

Tapping or ticking A A — B B B

Timing chain and chain ten-sioner noise

Timing chain cracks and wearTiming chain tensioner operation

EM-47EM-47

Front of engine

Squeak-ing or fizz-ing

A B — B — C

Drive belt (Sticking or slip-ping)

Drive belt deflectionEM-117

Creaking A B A B A B Drive belt (Slipping)

Idler pulley bearing op-eration

SquallCreak A B — B A B

Water pump noise

Water pump operation CO-19



EM-16

< PERIODIC MAINTENANCE > [HR16DE]DRIVE BELT

PERIODIC MAINTENANCEDRIVE BELTExploded View INFOID:0000000007575588

Removal and Installation INFOID:0000000007575589

REMOVAL1. Remove wheel and tire (RH). Refer to WT-39, "Adjustment".2. Remove the fender protector (RH) front side clip. Refer to EXT-26, "Exploded View".3. Loosen the lock nut (A), and then release the belt tension by

turning the adjusting bolt (B).

4. Remove the drive belt.

INSTALLATION

1. Generator 2. Water pump 3. Crankshaft pulley4. A/C compressor (with A/C models)

Idler pulley (without A/C models)5. Idler pulley 6. Drive belt

JSBIA1053ZZ

(1) : Generator(2) : Water pump(3) : Crankshaft pulley

(4) : A/C compressor (with A/C models): Idler pulley (without A/C models)

(5) : Idler pulley(6) : Drive belt

PBIC3643E



DRIVE BELT

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1. Pull the idler pulley in the loosening direction, and then tempo-rarily tighten the lock nut (A) to the following torque.

NOTE:Do not move the lock nut from the temporary tightened position. Go to step 2.

2. Install the drive belt on each pulley.CAUTION:• Check that there is no oil, grease, or coolant, etc. in pulley grooves.• Check that the belt seats securely inside the groove on each pulley.

3. Adjust drive belt tension by turning the adjusting bolt. Refer to EM-18, "Adjustment".CAUTION:• Perform the belt tension adjustment with the lock nut temporarily tightened to the torque specifi-

cation listed in step 1 which prevents the idler pulley from tilting.• When checking immediately after installation, first adjust it to the specified value. Then, after

turning crankshaft two turns or more, readjust to the specified value to avoid variation in deflec-tion between pulleys.

4. Tighten the lock nut to final tightening specification.

5. Check that belt tension is within the specification. Refer to EM-117, "Drive Belt".

Inspection INFOID:0000000007575590

• Inspection should be done only when engine is cold or over 30minutes after the engine is stopped.

• Visually check belt for wear, damage, and cracks on inside andedges.

• Turn crankshaft pulley clockwise twice, and check that the tension on all pulleys equalizes before testing. • When measuring deflection, apply 98.1 N (10 kg, 22 lb) at the ( ) marked point.• Measure the belt tension and frequency with acoustic tension gauge at the ( ) marked point.CAUTION:• When the tension and frequency are measured, the acoustic tension gauge should be used.• When checking immediately after installation, first adjust it to the specified value. Then, after turning

crankshaft two turns or more, readjust to the specified value to avoid variation in deflection betweenpulleys.

Lock nut (A)(Temporary tightening)

: 4.4 N·m (0.45 kg-m, 39 in-lb)



(5) : Idler pulley(6) : Drive belt(B) : Adjusting bolt

Lock nut (Final tightening) : 34.8 N·m (3.5 kg-m, 26 ft-lb)

PBIC3643E



(5) : Idler pulley(6) : Drive belt

Belt deflection/belt tension and frequency : Refer to EM-117, "Drive Belt".

PBIC3642E



EM-18

< PERIODIC MAINTENANCE > [HR16DE]DRIVE BELT

Adjustment INFOID:0000000007575591

CAUTION:• When belt is replaced with new one, adjust belt tension to the value for “New belt,” because new belt

will not fully seat in the pulley groove.• When tension of the belt being used exceeds “Limit,” adjust it to the value for “After adjusted.”• When installing a belt, check it is correctly engaged with the pulley groove.• Never allow oil or engine coolant to get on the belt.• Never twist or bend the belt strongly.1. Remove the fender protector (RH) front side clip. Refer to EXT-26, "Removal and Installation".2. Tighten lock nut (A) temporarily to the following torque.

3. Adjust the belt tension by turning the adjusting bolt. Refer to EM-117, "Drive Belt".CAUTION:• When checking immediately after installation, first adjust it to the specified value. Then, after

turning crankshaft two turns or more, readjust to the specified value to avoid variation in deflec-tion between pulleys.

• When the tension adjustment is performed, the lock nut should be in the condition at Step 2. Ifthe tension adjustment is performed when the lock nut is loosened more than the temporarytightening, the idler pulley tilts and the correct tension adjustment cannot be performed.

4. Tighten the lock nut to final tightening specification.

Location Location of adjuster and tightening method

Drive belt Adjusting bolt on idler pulley

Lock nut (A)(Temporary tightening) : 4.4 N·m (0.45 kg-m, 39 in-lb)



(5) : Idler pulley(6) : Drive belt(B) : Adjusting bolt

PBIC3643E

Lock nut (Final tightening) : 34.8 N·m (3.5 kg-m, 26 ft-lb)



AIR CLEANER FILTER

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AIR CLEANER FILTERExploded View INFOID:0000000007575686


REMOVAL1. Unhook clips (A) and pull the air cleaner cover upward (1).

1. Clamp 2. PCV hose 3. Clamp4. Mount rubber 5. Air duct (inlet) 6. Air cleaner body7. Grommet 8. Air cleaner filter 9. Air cleaner cover10. Mass air flow sensor 11. Air duct 12. ClampA. To electric throttle control actuator B. To rocker cover

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< PERIODIC MAINTENANCE > [HR16DE]AIR CLEANER FILTER

2. Remove the air cleaner filter (1) from the air cleaner body.

INSTALLATIONInstallation is in the reverse order of removal.NOTE:Check that the air cleaner filter is securely placed in the air cleaner body.

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SPARK PLUG

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SPARK PLUGExploded View INFOID:0000000007733081


REMOVAL1. Remove ignition coil. Refer to EM-44, "Removal and Installation".

CAUTION:Never drop or shock ignition coil.

2. Remove spark plug using a suitable tool.

CAUTION:Never drop or shock spark plug.

INSPECTION AFTER REMOVAL• Do not use a wire brush for cleaning.

• If the spark plug tip is covered with carbon, a spark plug cleaner may be used.

1. Ignition coil 2. Spark plug

PBIC3662E

Diameter (a) : 14 mm (0.55 in)

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SMA773C



EM-22

< PERIODIC MAINTENANCE > [HR16DE]SPARK PLUG

• Checking and adjusting spark plug gap is not required betweenchange intervals. Do not adjust the gap; replace the spark plug asnecessary if out of specification.

INSTALLATIONInstallation is in the reverse order of removal.CAUTION:Do not drop or shock the spark plug.

*: Always check with the Parts Department for the latest parts information.

Cleaner air pressure : Less than 588 kPa (6 kg/cm2, 85 psi)Cleaning time : Less than 20 seconds

SMA806CA

Make NGK

Standard type* PLZKAR6A-11

Gap (nominal) 1.1 mm (0.043 in)



DRIVE BELT IDLER PULLEY

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< REMOVAL AND INSTALLATION > [HR16DE]

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REMOVAL AND INSTALLATIONDRIVE BELT IDLER PULLEYExploded View INFOID:0000000007733082


REMOVAL1. Remove the fender protector. Refer to EXT-26, "Removal and Installation".2. Remove the air duct inlet assembly. Refer to EM-25, "Removal and Installation".3. Remove drive belt. Refer to EM-16, "Removal and Installation".4. Remove the lock nut, and then remove the plate, idler pulley, and washer.5. Remove the center shaft together with the spacer and the adjusting bolt.

INSTALLATION

1 : Generator bracket2 : Center shaft3 : Spacer4 : Adjusting bolt5 : Washer6 : Idler pulley7 : Plate

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EM-24

< REMOVAL AND INSTALLATION > [HR16DE]DRIVE BELT IDLER PULLEY

1. Insert the center shaft (1) into the slide groove of the spacer (2).Fully screw in the adjusting bolt (3) in the belt loosening direc-tion ( ).• At that time, place the flange (a) of the adjusting bolt and the

seat (b) of the center shaft on the spacer.2. Place each surface (c and d) of the spacer on the generator

bracket. Install the washer, idler pulley, and plate, and then tem-porarily tighten the lock nut.

3. Installation is in the reverse order of removal.

Lock nut (Temporary tightening) : 4.4 N·m (0.45 kg-m, 39 in-lb)

PBIC3885E



AIR CLEANER AND AIR DUCT

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AIR CLEANER AND AIR DUCTExploded View INFOID:0000000007733084


REMOVALNOTE:Mass air flow sensor is removable as an assembly with the air cleaner cover. 1. Remove air duct (inlet) from the air cleaner body.2. Disconnect PCV hose from the air duct.3. Remove the air duct (between air cleaner case and electric throttle control actuator).

• Add matching marks if necessary for easier installation.4. Remove air cleaner assembly with the following steps:a. Disconnect mass air flow sensor harness connector.b. Remove the two air cleaner body bolts.c. Pull up on the air cleaner assembly to disengage it from the grommet and remove the air cleaner assem-

bly.CAUTION:• Never shock the mass air flow sensor.• Never disassemble the mass air flow sensor.• Never touch the sensor of the mass air flow sensor.

INSPECTION AFTER REMOVALInspect air duct (inlet) and air duct for cracks, tears, or breaks.

1. Clamp 2. PCV hose 3. Clamp4. Mount rubber 5. Air duct (inlet) 6. Air cleaner body7. Grommet 8. Air cleaner filter 9. Air cleaner cover10. Mass air flow sensor 11. Air duct 12. ClampA. To electric throttle control actuator B. To rocker cover

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EM-26

< REMOVAL AND INSTALLATION > [HR16DE]AIR CLEANER AND AIR DUCT

Replace air duct (inlet) and air duct if any problems are found.

INSTALLATIONInstallation is in the reverse order of removal.NOTE:Align marks, attach each joint and screw clamps firmly.



INTAKE MANIFOLD

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INTAKE MANIFOLDExploded View INFOID:0000000007575602


REMOVALNOTE:When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-ing.1. Remove air duct (inlet), air duct and air cleaner assembly. Refer to EM-25, "Removal and Installation".2. Disconnect water hoses from electric throttle control actuator.

CAUTION:• Perform this step when the engine is cold.• Never spill engine coolant on drive belt.

3. Remove electric throttle control actuator.CAUTION:• Handle carefully to avoid any shock to electric throttle control actuator.• Never disassemble electric throttle control actuator.

4. Disconnect harness connector and vacuum hose from EVAP purge control solenoid valve.CAUTION:Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.

5. Disconnect vacuum hose for brake booster from intake manifold.

1. EVAP canister purge volume control solenoid valve

2. Hose clamp 3. Vacuum hose

4. PCV hose 5. Hose clamp 6. Intake manifold support7. Gasket 8. Intake manifold 9. Electric throttle control actuator10. Gasket 11. EVAP service portA. To air duct B. To centralized under-floor piping C. To brake boosterD. To air duct E. To rocker cover

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EM-28

< REMOVAL AND INSTALLATION > [HR16DE]INTAKE MANIFOLD

6. Remove intake manifold mounting bolts at the rocker cover.

7. Loosen mounting bolts in reverse order as shown in the figure.CAUTION:Cover engine openings to avoid entry of foreign materials.

8. Remove intake manifold.9. Remove EVAP purge control solenoid valve from intake manifold if necessary.

CAUTION:Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.

10. Remove intake manifold support (1) if necessary.CAUTION:The intake manifold support functions as a guide for install-ing the intake manifold.

INSTALLATIONInstallation is in the reverse order of removal.Intake Manifold1. Install the new gasket to the intake manifold.

• Align the protrusions used for checking gasket installation con-dition with the clearance grooves (A) of the intake manifoldmounting groove.

CAUTION:Do not reuse the gasket.NOTE:New gasket for electronically-controlled throttle can be installedwhen the electronically-controlled throttle is installed.

2. Place the intake manifold into position.CAUTION:

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INTAKE MANIFOLD

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Check that the oil level gauge guide is not detached from the securing clip of the water inlet due tointerference of intake manifold.

3. Tighten the bolts to specification in the numerical order asshown.

4. Tighten the intake manifold mounting bolts to specification at therocker cover.

Electric Throttle Control Actuator• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-

tric throttle control actuator. Refer to EC-118, "Work Procedure".• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing

electric throttle control actuator. Refer to EC-119, "Work Procedure".

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E M - 3 0

< REMOVAL AND INSTALLATION > [HR16DE]EXHAUST MANIFOLD

EXHAUST MANIFOLDExploded View INFOID:0000000007575604


REMOVAL1. Remove air duct (inlet), air duct and air cleaner assembly. Refer to EM-25, "Exploded View".2. Remove exhaust center tube and front tube. Refer to EX-5, "Exploded View".3. Remove the air-fuel ratio sensor harness bracket from the cylinder head on the right rear side.4. Remove exhaust manifold cover.5. Disconnect the harness from air-fuel ratio sensor 1.6. Remove exhaust manifold side mounting bolt of exhaust manifold stay.7. Remove exhaust manifold.

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1. Exhaust manifold cover 2. Harness bracket 3. Air-fuel ratio sensor 14. Exhaust manifold stay 5. Heat insulator 6. Exhaust manifold7. Exhaust manifold cover 8. Gasket : Engine front



EXHAUST MANIFOLD

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• Loosen nuts in reverse order as shown in the figure.

8. Use Tool (A) to remove the air-fuel ratio sensor 1 (if necessary).

CAUTION:• Handle the air-fuel ratio sensor carefully and avoid

impacts.• Before installing a new air-fuel ratio sensor 1, clean the

exhaust tube threads using suitable tool and approvedanti-seize lubricant.

• If air-fuel ratio sensor is dropped onto a hard surface,such as a concrete floor, from a height of 0.5 m or more,discard the sensor and use a new one.

9. Remove exhaust manifold gasket and discard. 10. Remove stud bolt using suitable tool from cylinder head (if necessary).

INSPECTION AFTER REMOVALMounting Surface Distortion• Using suitable tools (A) and (B), check the surface distortion of the

exhaust manifold mating surface as shown.

• Replace exhaust manifold if it exceeds the limit.

INSTALLATIONInstallation is in the reverse order of removal. Note the following:Exhaust manifold

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Tool number : KV10117100 ( — )

Oxygen sensor thread cleaner : — (J-43897-12)Oxygen sensor thread cleaner : — (J-43897-18)

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Limit : Refer to EM-118, "Exhaust Manifold".

PBIC3530J



EM-32

< REMOVAL AND INSTALLATION > [HR16DE]EXHAUST MANIFOLD

1. Tighten nuts in numerical order as shown.

2. Tighten nuts in numerical order to the specified torque again.

Air-fuel ratio sensor 1• Use Tool (A) to install the air-fuel ratio sensor 1 (if removed).

CAUTION:• Handle it carefully and avoid impacts.• Before installing a new air-fuel ratio sensor 1, clean the

exhaust tube threads using suitable tool and approved anti-seize lubricant.

• Do not over-tighten the air-fuel ratio sensor 1. Doing so maydamage the air-fuel ratio sensor 1, resulting in the MIL com-ing on.

INSPECTION AFTER INSTALLATIONInspection• Start engine and raise engine speed to check for exhaust leaks.

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Oxygen sensor thread cleaner : — (J-43897-12)Oxygen sensor thread cleaner : — (J-43897-18)

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OIL PAN (LOWER)

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OIL PAN (LOWER)Exploded View INFOID:0000000007575607


REMOVALWARNING:• Be careful not to get burned, engine coolant and engine oil may be hot.

1. Rear oil seal 2. O-ring 3. Oil pan (upper)4. Oil pump chain tensioner (for oil

pump drive chain)5. Oil pump drive chain 6. Crankshaft key

7. Crankshaft sprocket 8. Oil pump sprocket 9. Oil pump10. O-ring 11. O-ring 12. Oil pan drain plug13. Drain plug washer 14. Oil pan (lower) 15. Oil filter16. Connector bolt 17. Oil cooler 18. O-ring19. Relief valve A. Refer to EM-47 B. Refer to LU-11C. Oil pan (lower) side

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EM-34

< REMOVAL AND INSTALLATION > [HR16DE]OIL PAN (LOWER)

• Prolonged and repeated contact with used engine oil may cause skin cancer; avoid direct skin con-tact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon aspossible.

1. Drain engine oil. Refer to LU-9, "Draining".2. Loosen mounting bolts in reverse order as shown.

3. Insert Tool (A) between oil pan (upper) and oil pan (lower).

CAUTION:• Do not damage mating surfaces.• Never insert a screwdriver. This damages the mating sur-

faces.4. Slide the Tool (A) by tapping on the side of tool with a suitable

tool to loosen the oil pan (lower).5. Remove oil pan (lower).

INSPECTION AFTER REMOVALClean debris from oil pan (lower) and from the strainer.

INSTALLATIONCAUTION:Do not reuse O-rings or washers.1. Use a scraper (A) to remove old liquid gasket from mating sur-

faces.• Also remove old liquid gasket from mating surface of oil pan

(upper).• Remove old liquid gasket from the bolt holes and threads.CAUTION:Never scratch or damage the mating surface when cleaningoff old liquid gasket.

: Engine front

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Tool number : KV10111100 (J-37228)

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OIL PAN (LOWER)

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2. Apply a continuous bead of liquid gasket (A) with a tube presseras shown.

Use Genuine Silicone RTV Sealant or equivalent.CAUTION:• The components must be installed within 5 minutes of the

liquid gasket application.• Do not confirm torque after the 5 minutes have elapsed.• Then allow 30 minutes for the liquid gasket to set before

adding oil to the engine.

3. Tighten bolts in numerical order as shown.

4. Install oil pan drain plug.• Refer to the figure for installation direction of drain plug washer. Refer to EM-33, "Exploded View".CAUTION:• Installation should be done within 5 minutes after applying liquid gasket.• Do not fill the engine with oil for at least 30 minutes after the oil pan (lower) is installed to allow

the sealant to cure.5. Add the specified oil after waiting for at least 30 minutes. Refer to MA-12, "Fluids and Lubricants".

INSPECTION AFTER INSTALLATION• Before starting engine, check oil/fluid levels, including engine coolant and engine oil. If less than required

quantity, fill to the specified level. Refer to MA-12, "Fluids and Lubricants".• Use procedure below to check for fuel leakage.• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-

age at connection points.• Start engine. With engine speed increased, check again for fuel leakage at connection points.• Run engine to check for unusual noise and vibration.

NOTE:If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guidemay generate a pounding noise during and just after engine start. However, this is normal. Noise will stopafter hydraulic pressure rises.

• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids includingengine oil and engine coolant.

• Bleed air from passages in lines and hoses, such as in cooling system.

1 : Oil pan (lower)a : 7.5 - 9.5 mm (0.295 - 0.374 in)b : 4.0 - 5.0 mm (0.157 - 0.197 in) diameter

: Engine outside

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: Engine front

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EM-36

< REMOVAL AND INSTALLATION > [HR16DE]OIL PAN (LOWER)

• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-ified level, if necessary.

• Summary of the inspection items:

*Power steering fluid, brake fluid, etc.

Item Before starting engine Engine running After engine stopped

Engine coolant Level Leakage Level

Engine oil Level Leakage Level

Transmission/transaxle fluid

A/T and CVT Models Leakage Level/Leakage Leakage

M/T Models Level/Leakage Leakage Level/Leakage

Other oils and fluids* Level Leakage Level

Fuel Leakage Leakage Leakage

Exhaust gas — Leakage —



FUEL INJECTOR AND FUEL TUBE

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FUEL INJECTOR AND FUEL TUBEExploded View INFOID:0000000007575610

CAUTION:Never remove or disassemble parts unless instructed.


WARNING:• Put a “CAUTION: FLAMMABLE” sign in the workshop.• Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher. • Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.

REMOVAL1. Release the fuel pressure. Refer to EC-126, "Work Procedure".2. Remove intake manifold. Refer to EM-27, "Removal and Installation".

1. Stud bolt 2. O-ring (green) 3. Fuel injector (front)4. Clip 5. Fuel injector (rear) 6. O-ring (black)7. Fuel tube protector 8. Fuel tube 9. Clamp10. Quick connector cap (engine side) 11. Fuel feed hose 12. Quick connector cap (floor piping-side)13. Fuel connector protector 14. Fuel pipe A. To centralized under-floor piping

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EM-38

< REMOVAL AND INSTALLATION > [HR16DE]FUEL INJECTOR AND FUEL TUBE

3. Disconnect fuel feed hose from fuel tube. Disconnect quick con-nector:

NOTE:There is no fuel return path.

a. Remove quick connector cap (engine side) (1) from quick con-nector connection.

b. Disconnect fuel feed hose from hose clamp.

c. With the sleeve (B) side of quick connector release (A) facingquick connector (2), install quick connector release (A) onto fueltube (1) as shown.

d. Insert quick connector release (A) into quick connector (2) untilsleeve (B) contacts and goes no further. Hold quick connectorrelease (A) in that position (D).CAUTION:Inserting quick connector release hard will not disconnectquick connector. Hold quick connector release where itcontacts and goes no further.

e. Draw and pull out quick connector (E) straight up from fuel tube(1).CAUTION:• Pull quick connector up (E) from holding position (C) as shown. • Never pull with lateral force applied. O-ring inside quick connector may be damaged.• Prepare container and cloth beforehand as fuel will leak out.• Discard O-ring, do not reuse.• Avoid fire and sparks.• Keep parts away from heat source. Be especially careful when welding is performed. • Never expose parts to battery electrolyte or other acids.• Never bend or twist connection between quick connector and fuel feed tube during installation

or removal.• Be sure to cover openings of disconnected fuel feed hose

(A) and fuel tube (C) with plug or plastic bag (B) to avoidfuel leaks and entry of foreign material.

4. Disconnect fuel feed hose from fuel pipe as follows:

1 : Quick connector cap (engine side)

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NOTE:There is no fuel return path.

a. Remove quick connector cap (floor piping side) (1) from quickconnector connection.

b. Disconnect fuel feed hose from hose clamp (1).

c. Hold the quick connector (1) while pushing in tabs (F), and pullout the hard tube (A).

CAUTION:• Inserting quick connector release hard will not disconnect

quick connector. Hold quick connector release where itcontacts and goes no further.

• The tube can be removed when the tabs are completelydepressed. Do not twist it more than necessary.

• Do not use any tools to remove the quick connector.• Keep the resin tube away from heat. Be especially careful

when welding near the tube.• Prevent acid such as battery electrolyte etc. from getting

on the resin tube.• Do not bend or twist the tube during installation and

removal.• Remove the remaining retainer only when the tube is

replaced.• When the tube is replaced, also replace the retainer.

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2 : RetainerB : Connection (cross-section)C : Resin tubeD : To under floor fuel lineE : To fuel tankG : Disconnection

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EM-40


• Be sure to cover openings of disconnected pipes withplug or plastic bag (B) to avoid fuel leaks and entry of for-eign material.

5. Disconnect harness connector from fuel injector.6. Remove fuel tube protector.

• Loosen mounting bolts in reverse order as shown.

7. Remove fuel injector and fuel tube assembly:

a. Loosen two nuts in reverse order as shown in the figure.b. Pull the fuel tube straight out until injector lower O-rings are

clear.c. Remove the nuts and the fuel tube.CAUTION:• When removing, be careful to avoid interference with fuel

injectors.• Use a shop cloth to absorb any fuel leaks from fuel tube.

8. Remove fuel injector from fuel tube:a. Open and remove clip (1).b. Remove fuel injectors (3) and (4) from fuel tube (2) by pulling

straight out.CAUTION:• Be careful with remaining fuel that may leak from fuel

tube.• Be careful not to damage fuel injector nozzle during

removal.• Never bump or drop fuel injector.• Never disassemble fuel injector.• Do not reuse O-rings.

INSTALLATIONCAUTION:Do not reuse O-rings.1. Note the following, and install new O-rings on the fuel injector.

CAUTION:

A :Fuel feed hoseC :Fuel tube

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: Engine front

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: Engine front

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• Upper and lower O-rings are different. Be careful not to interchange them.

• Handle O-ring with bare hands. Never wear gloves.• Lubricate O-ring with new engine oil.• Never clean O-ring with solvent.• Check that O-ring and its mating part are free of foreign material.• When installing O-ring, be careful not to scratch it.• Do not twist or stretch O-ring. If O-ring was stretched while it was being attached, allow it to

retract before inserting it into fuel tube.• Insert O-ring straight into fuel tube. Never angle or twist it.

2. Install fuel injector (4) to fuel tube (1):a. Insert new clip (2) into clip mounting groove (G) on fuel injector

(4).• Insert new clip (2) so that protrusion (F) of fuel injector

matches cut-out (D) of clip.

CAUTION:• Never reuse clip. Replace it with a new one.• Be careful to keep clip from interfering with O-ring. If

interference occurs, replace O-ring.b. Insert fuel injector (4) into fuel tube (1) with clip (2) attached.

• Insert fuel injector (4) while matching it to the axial center.• Insert fuel injector (4) so that protrusion (B) of fuel tube

matches cut-out (C) of clip (2).• Check that fuel tube flange (A) is securely located in flange

groove (E) on clip (2).

c. Check that installation is complete by checking that fuel injector (4) does not rotate or come off.3. Set fuel tube and fuel injector assembly in position for installation on cylinder head.

CAUTION:For installation, be careful not to interfere with fuel injector nozzle.• Tighten mounting bolts in numerical order as shown.

4. Install fuel tube protector.

Fuel tube side : BlackNozzle side : Green

3 : O-ring (black)5 : O-ring (green)

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: Engine front

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EM-42


• Tighten mounting bolts in numerical order as shown.

5. Connect harness connector to fuel injector.6. Connect fuel feed tube (engine side):a. Check for damage or foreign material on the fuel tube and quick connector.b. Apply new engine oil lightly to area around the top of fuel tube.c. Align center to insert quick connector straight into fuel tube.

• Insert quick connector (1) to fuel tube until the top spool (C) onfuel tube is inserted completely and the 2nd level spool (D) ispositioned slightly below quick connector bottom end.

CAUTION:• Hold in position (A) as shown when inserting fuel tube

into quick connector.• Carefully align center to avoid inclined insertion to pre-

vent damage to O-ring inside quick connector.• Insert until you hear a “click” sound and actually feel

the engagement.d. To avoid misidentification of engagement with a similar sound, pull quick connector hard by hand. Check it

is completely engaged (connected) so that it does not come out from fuel tube.e. Install quick connector cap (engine side) (1) to quick connector

connection.• Install quick connector cap (engine side) (1) with the side

arrow facing quick connector side (fuel feed tube side) asshown.CAUTION:• Check that the quick connector and fuel tube are

securely engaged with the quick connector cap (engineside) mounting groove.

• If the quick connector cap (engine side) cannot beinstalled easily the quick connector may not be con-nected correctly. Remove and reconnect.

f. Install fuel feed hose to hose clamp.7. Connect fuel feed tube (floor piping side):a. Check the connection for damage or any foreign materials.b. Align the quick connector with the tube, then insert the connector straight into the centralized under floor

piping until a click is heard.

: Engine front

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B : Upright insertionE : Correctly connected

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c. After connecting, check that the connection is secure:• Visually confirm that the two retainer tabs are connected to the

connector.• With the fuel feed hose not fixed to the clamp, pull quick con-

nector (A) hard by hand to check that the quick connector (A)is not disconnected from the centralized underfloor piping (1)and that the quick connector (1) is securely connected.

8. Install remaining parts in the reverse order of removal.

INSPECTION AFTER INSTALLATIONCheck on Fuel Leaks1. Turn ignition switch ON with the engine stopped. Ensure there are no fuel leaks at fuel pipe connection

points.NOTE:Use mirrors for checking points out of clear sight.

2. Start the engine and increase engine speed. Check again that there are no fuel leaks.CAUTION:Never touch the engine immediately after stopped, as the engine becomes extremely hot.

PBIC3795E



EM-44

< REMOVAL AND INSTALLATION > [HR16DE]IGNITION COIL, SPARK PLUG AND ROCKER COVER

IGNITION COIL, SPARK PLUG AND ROCKER COVERExploded View INFOID:0000000007575613


REMOVAL1. Disconnect the battery negative terminal.2. Remove intake manifold. Refer to EM-27, "Exploded View". 3. Remove ignition coil.

CAUTION:• Never drop or shock ignition coil.• Never disassemble ignition coil.

4. Remove fuel tube protector. Refer to EM-37, "Exploded View".5. Remove PCV hose from rocker cover.

1. Ignition coil 2. Spark plug 3. Rocker cover4. Hose cramp 5. PCV hose 6. PCV valve7. O-ring 8. Gasket 9. Oil filler cap10. O-ring 11. Intake camshaft position sensor 12. Exhaust camshaft position sensor13. Clip A. To intake manifold

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IGNITION COIL, SPARK PLUG AND ROCKER COVER

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6. Remove PCV valve, if necessary.7. Remove rocker cover.

• Loosen bolts in reverse order as shown in the figure.

8. Remove rocker cover gasket from rocker cover.9. Use scraper to remove all traces of liquid gasket from cylinder head and front cover.

CAUTION:Never scratch or damage the mating surface when cleaning off old liquid gasket.

INSTALLATIONCAUTION:Do not reuse O-ring.1. Install the rocker cover:a. Press gasket onto the bosses for the rocker cover bolt holes as

shown to prevent the gasket from dropping off.

b. Apply liquid gasket to the cylinder head (1) and front cover (2) asshown.

Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-15, "Recommended Chemical Products and Sealants".CAUTION:• The components must be installed within 5 minutes of the

liquid gasket application.• Then allow 30 minutes for the liquid gasket to set before

putting oil in the engine.

c. Install rocker cover to cylinder head.CAUTION:Check that the gasket has not slipped out of position.

: Engine front

JPBIA4135ZZ

: Engine front

JPBIA4136ZZ

a : 2.5 - 3.5 mm diameter

JPBIA4137ZZ



EM-46

< REMOVAL AND INSTALLATION > [HR16DE]IGNITION COIL, SPARK PLUG AND ROCKER COVER

• Tighten bolts in numerical order in two separate stages asshown.

2. Installation of the remaining components is in the reverse order of removal.

: Engine front

JPBIA4135ZZ



TIMING CHAIN

EM-47


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TIMING CHAINExploded View INFOID:0000000007575615


CAUTION:The rotation direction indicated in the text is as viewed from the engine front.

REMOVALNOTE:When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-ing.1. Remove front road wheel (RH).

1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH)4. Camshaft sprocket (INT) 5. Plug 6. Front oil seal7. Crankshaft pulley 8. Crankshaft pulley bolt 9. Front cover10. Crankshaft sprocket 11. Crankshaft sprocket key 12. Oil pump sprocket13. Oil pump drive chain 14. Oil pump drive chain tensioner 15. Timing chain16. Timing chain tension guide A. Refer to installation procedure. Refer

to EM-47

JPBIA4095GB



EM-48

< REMOVAL AND INSTALLATION > [HR16DE]TIMING CHAIN

2. Remove front fender protector (RH). Refer to EXT-26, "Removal and Installation".3. Drain engine oil. Refer to LU-9, "Draining".

CAUTION:• Perform this step when engine is cold.• Do not spill engine oil on drive belt.

4. Drain coolant. Refer to CO-8, "Draining Engine Coolant".5. Remove the following parts.

• Intake manifold. Refer to EM-27, "Removal and Installation".• Drive belt. Refer to EM-16, "Removal and Installation".• Rocker cover. Refer to EM-44, "Exploded View".• Water pump pulley. Refer to CO-19, "Removal and Installation".

6. Support the bottom surface of engine using a transmission jack, and then remove the engine mountingbracket and insulator (RH). Refer to EM-82, "Exploded View".

7. Set No. 1 cylinder at TDC of its compression stroke:a. Rotate crankshaft pulley (2) clockwise and align TDC mark

(without paint mark) (A) to timing indicator (1) on front cover.

b. Check the matching marks on each camshaft sprocket are posi-tioned as shown.

• If not, rotate crankshaft pulley one more turn to align matchingmarks to the positions.

8. Remove crankshaft pulley:a. Secure crankshaft pulley (1) using suitable tool (A).b. Loosen and pull out crankshaft pulley bolt.

CAUTION:Never remove the mounting bolts as they will be used as asupporting point for the pulley puller.

B : White paint mark (Not use for service)

PBIC3673E

1 : Timing chain 2 : Camshaft sprocket (EXH)3. : Camshaft sprocket (INT)A : Matching mark (Peripheral groove)B : Pink linkC : Matching mark (Peripheral groove)

JPBIA4138ZZ

PBIC3710E



TIMING CHAIN

EM-49


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c. Attach Tool (A) in the M 6 thread hole on crankshaft pulley, andremove crankshaft pulley.

9. Remove front cover:a. Loosen bolts in the reverse order as shown.

b. Cut liquid gasket by prying the position ( ) as shown, and thenremove the front cover.

10. Remove front oil seal from front cover using a suitable tool.CAUTION:Be careful not to damage the front cover.

B : M6 bolt


PBIC3711E

JPBIA4139ZZ

JPBIA4140ZZ



EM-50


11. Remove chain tensioner (1):a. Fully push down the chain tensioner lever (A), and then push the

plunger (C) into the inside of tensioner.• The tab (B) is released by fully pushing the lever down. Then

the plunger can be moved.b. Pull up the lever to align its hole position with the body hole posi-

tion.• When the lever hole is aligned with the body hole position, the

plunger is secured.• When the protrusion parts of the plunger ratchet and the tab

face each other, both hole positions are not aligned. At thattime, correctly engage them and align these hole positions byslightly moving the plunger.

c. Insert the stopper pin (D) into the body hole through the lever hole, and then secure the lever at the upperposition.NOTE:A hexagonal wrench of 2.5 mm (0.098 in) is used as a stopper pin (D).

d. Remove chain tensioner.12. Remove the timing chain tension guide (2) and the timing chain

slack guide (1).

13. Remove the timing chain (2).• Pull the timing chain slack toward the camshaft sprocket

(EXH) (1), and then remove the timing chain and start theremoval from camshaft sprocket (EXH) side.

CAUTION:Never rotate crankshaft or camshaft while timing chain isremoved. It causes interference between valve and piston.

14. Remove the crankshaft sprocket and the oil pump drive related parts:a. Remove oil pump drive chain tensioner (1).

• Pull out from the shaft (B) and spring attaching holes (A).

PBIC3713E

JPBIA4141ZZ

JPBIA4142ZZ

JPBIA4143ZZ



TIMING CHAIN

EM-51


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b. Hold the top of the oil pump shaft using the socket (size: E8),and then loosen the oil pump sprocket nut and remove it.

c. Remove the crankshaft sprocket (1), the oil pump drive chain(2), and the oil pump sprocket (3) at the same time.

INSTALLATIONNOTE:For installation follow the relationship between the matching mark oneach timing chain and that of the corresponding sprocket, with thecomponents installed.

1. Install the crankshaft sprocket and the oil pump drive related parts:a. Install the crankshaft sprocket (1), the oil pump drive chain (2),

and the oil pump sprocket (3) at the same time.

• Install the crankshaft sprocket so that its invalid gear area (A)is toward the back of the engine.

• Install the oil pump sprocket so that its protrusion faces thefront of engine.

NOTE:There is no matching mark in the oil pump drive related parts.

JPBIA4230ZZ

1 : Camshaft sprocket (EXH)2 : Timing chain 3 : Timing chain slack guide4 : Chain tensioner5 : Crankshaft sprocket6 : Oil pump drive chain7 : Oil pump sprocket8 : Timing chain tension guide9 : Camshaft sprocket (INT)A : Matching mark (Peripheral groove)B : Pink linkC : Matching mark (Peripheral groove)D : Orange linkE : Matching mark (stamp)F : Crankshaft key (point straight up)

JPBIA4223ZZ

: Engine front

JPBIA5248ZZ



EM-52


b. Hold the top of the oil pump shaft using the socket (size: E8),and then tighten the oil pump sprocket nut.

c. Install oil pump drive chain tensioner (1).• Insert the body into the shaft (B) while inserting the spring into

the attaching hole (A) of cylinder block front surface.• Check that the tension is applied to the oil pump drive chain

after installing.

2. Install timing chain:

• Install by aligning matching marks on each sprocket and tim-ing chain.

• If these matching marks are not aligned, rotate the camshaftslightly to correct the position.

CAUTION:• After the matching marks are aligned, keep them aligned

by holding them. • To avoid skipped teeth, do not rotate crankshaft and cam-

shaft until front cover is installed.

3. Install timing chain tension guide (2) and timing chain slackguide (1).

1 : Crankshaft sprocket2 : Oil pump drive chain 3 : Oil pump sprocket

JPBIA4230ZZ

JPBIA4143ZZ

A : Matching mark (Peripheral groove)B : Pink linkC : Matching mark (Peripheral groove)D : Orange linkE : Matching mark (stamp)F : Crankshaft key (point straight up)

JPBIA4144ZZ

JPBIA4141ZZ



TIMING CHAIN

EM-53


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4. Install chain tensioner (1).• Secure the plunger at the most compressed position using a

stopper pin (A), and then install it.• Pull out the stopper pin after installing the chain tensioner.

5. Check matching mark position of timing chain and each sprocket again.6. Install the front oil seal to the front cover. Refer to EM-71, "FRONT OIL SEAL : Removal and Installation".7. Install front cover with the following procedure:a. Apply a continuous bead of liquid gasket to the front cover as

shown. Use Genuine Silicone RTV Sealant or equivalent. Refer toGI-15, "Recommended Chemical Products and Sealants".

PBIC3722E

1 : Cylinder head2 : Cylinder block3 : Oil pan (upper)

A : Liquid gasket application area [3.0 - 4.0 mm (0.12 - 0.16 in) diam-eter]

Tool number : WS39930000 ( — )

JPBIA4145ZZ



EM-54


b. Apply a continuous bead of liquid gasket to front cover asshown. Use Genuine Silicone RTV Sealant or equivalent. Refer toGI-15, "Recommended Chemical Products and Sealants".

c. Tighten bolts in the numerical order as shown.d. After all bolts are tightened, retighten them to specified torque in

numerical order as shown.CAUTION:Be sure to wipe off any excessive liquid gasket leaking tosurface.

8. Insert crankshaft pulley by aligning with crankshaft key. • When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).

CAUTION:Never damage front oil seal lip section.

9. Tighten crankshaft pulley bolt:• Secure crankshaft pulley with a suitable tool and tighten crankshaft pulley bolt.

a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.b. Tighten crankshaft pulley bolt.

1 : Front cover edgeA : Liquid gasket application areab : 4.0 - 5.6 mm

c : Liquid gasket application area [3.0 - 4.0 mm (0.12 - 0.16 in) diame-ter]

JPBIA4146ZZ

JPBIA4139ZZ

Crankshaft pulley bolt : 35.0 N·m (3.6 kg-m, 26 ft-lb)



TIMING CHAIN

EM-55


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c. Put a paint mark (B) on crankshaft pulley, mating with any one ofsix easy to recognize angle marks (A) on crankshaft bolt flange(1).

d. Turn another 60 degrees clockwise (angle tightening).• Check the tightening angle with movement of one angle mark.

10. Check that crankshaft turns smoothly by rotating by hand clockwise.11. Installation of the remaining components is in the reverse order of removal.






• Bleed air from passages in lines and hoses, such as in cooling system.• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-

ified level, if necessary.• Summary of the inspection items:


PBIC3726E












EM-56

< REMOVAL AND INSTALLATION > [HR16DE]CAMSHAFT

CAMSHAFTExploded View INFOID:0000000007575618


CAUTION:The rotation direction indicated in the procedure is as viewed from the engine front.

REMOVAL1. Hold the bottom surface of the engine with a jack to remove the right engine mount assembly and the

insulator. Refer to EM-82, "Exploded View".2. Remove rocker cover. Refer to EM-44, "Exploded View".3. Place cylinder No. 1 at TDC of its compression stroke:

1. Camshaft bracket (No. 2 to 5) 2. Camshaft bracket (No. 1) 3. Camshaft sprocket (EXH)

4. Exhaust valve timing control sole-noid valve 5. O-ring 6. Camshaft sprocket (INT)

7. Plug (EXH) 8. Washer (EXH) 9. Oil filter (for exhaust valve timing control solenoid valve)

10. Cylinder head 11. Oil filter (for intake valve timing control solenoid valve) 12. Washer (INT)

13. Plug (INT) 14. O-ring 15. Intake valve timing control solenoid valve

16. Bracket 17. Valve lifter 18. Camshaft (INT)19. Camshaft (EXH) A. Refer to EM-56

JPBIA4096GB



CAMSHAFT

EM-57


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a. Rotate crankshaft pulley (2) clockwise and align TDC mark(without paint mark) (A) to timing indicator (1) on front cover.

b. Check that the matching marks on each of the camshaft sprock-ets are in the position as shown.

• If not, rotate crankshaft pulley one more turn to align matchingmarks to the positions as shown.

c. Paint matching marks (A) on the timing chain links.4. Remove crankshaft pulley. Refer to EM-47, "Exploded View".5. Remove front cover. Refer to EM-47, "Exploded View".6. Secure the plunger of chain tensioner in the fully compressed position. Then, loosen the timing chain ten-

sion.a. Fully push down the lever (B) of chain tensioner (2) from the

plug hole, and then insert the stopper pin (A) into the body sidehole and secure the lever at the lowest position.

• The tab is released by fully pushing the lever down. As aresult, the plunger (1) can be moved.

NOTE:Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pinas an example.CAUTION:The stopper pin must use a shape that cannot fall in thefront cover if dropped.

b. Turn the crankshaft pulley (2) counterclockwise with the cam-shaft (EXH) (1) held. Apply the tension to the timing chain, andthen push the plunger into the inside of chain tensioner.CAUTION:Hold the camshaft hexagonal part (A), and then secure thecamshaft.

B : White paint mark (Not used for service)

PBIC3673E

1. : Timing chain 2. : Camshaft sprocket (EXH)3. : Camshaft sprocket (INT)A : Matching mark (Peripheral groove)B : Pink linkC : Matching mark (Peripheral groove)

C : Front cover has been removed for clarity.

JPBIA4138ZZ

PBIC3676E

PBIC3677E



EM-58


c. Pull out the stopper pin (A) of chain tensioner (2) side from plughole. Lift the lever (B) up to align its hole position with the hole ofthe body.

• When the lever hole (C) is aligned with the body hole position,the plunger (1) is secured.

• When the protrusion parts of the plunger ratchet and the tabface each other, both hole positions are not aligned. At thattime, correctly engage them and align these hole positions byslightly moving the plunger.

d. Insert the stopper pin into the body hole through the lever hole, and then secure the lever at the upperposition.

7. Remove timing chain.8. Remove camshaft sprocket (EXH) (1).

CAUTION:• Hold the camshaft hexagonal part (A), and then secure the

camshaft.• Never rotate crankshaft and camshaft separately, so as

not to contact valve with piston.NOTE:The timing chain with the front cover installed is not disengagedfrom the crankshaft sprocket and it is not dropped into the frontcover. Therefore, the timing chain tension holding device is notnecessary.

9. Turn the camshaft sprocket (INT) to the most advanced position.CAUTION:Installation and removal of the camshaft sprocket (INT) must be done in the most advanced posi-tion. Make sure to follow the procedure exactly.• The sprocket (C) and vane (camshaft coupling) (B) are

designed to spin and move within the range of a certainangle.

• With the engine stopped and the vane in the mostretarded angle, it will not spin because it is locked to thesprocket side by the internal lock pin (A).

• If the camshaft sprocket mounting bolts are turned in thesituation described above, the lock pin will become dam-aged and cause malfunctions because of the increasedhorizontal load (cutting force) on the lock pin.

• Put the camshaft sprocket (INT) in the most advanced position:a. Remove camshaft bracket (No. 1) (1).

• Loosen the bolts in several steps, and then remove them.

D : Front cover has been removed for clarity.

PBIC3772E

JPBIA4160ZZ

PBIC3679E

: Engine front

PBIC3680E



CAMSHAFT

EM-59


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b. Apply the following air pressure to the No. 1 journal oil hole (A)of camshaft (INT) (1) shown using an air gun.

• Apply the air pressure into the oil hole on the second groovefrom the front of camshaft thrust (B).

• Proceed all the way through step “e” with the air pressure on.• Attach the rubber nozzle narrowed to the top of the air gun to

prevent air leakage from the oil hole (A). Securely apply the airpressure to the oil hole.

WARNING:Eye protection should be worn as needed.CAUTION:• There are other oil holes in the side grooves. Never use the incorrect oil holes.• Be sure not to damage the oil path with the tip of the air gun.• Wipe all the oil off the air gun to prevent oil from being blown all over along with the air, and the

area around the air gun should be wiped with a rag when applying air pressure. Eye protectionshould be worn as needed.

NOTE:The air pressure is used to move the lock pin into the disengage position.

c. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alter-nately.

• Finally rotate the sprocket of the camshaft sprocket (INT)counterclockwise [the direction shown by the arrow ( )].

• Perform the work while continuously applying the air pressureto the oil hole.

• If the lock pin is not released, tap the camshaft sprocket (INT)lightly with a plastic hammer (A).

• If the camshaft sprocket (INT) is not rotated counterclockwiseeven if the above procedures are performed, check the airpressure and the oil hole position.

d. While doing the above, once you hear a click (the sound of theinternal lock pin disengaging) from inside the camshaft sprocket(INT), start turning the camshaft sprocket (INT) in the counter-clockwise direction in the most advanced angle position.

• Keep the air pressure on.• If there is no click, as soon as the vane side (camshaft side)

starts moving independently of the sprocket, the lock pin hasbecome disengaged.

Air pressure : 300 kPa (3.1 kg/cm2, 44 psi) or more

JPBIA4150ZZ

(A) : Air gun (B) : Rubber nozzle

JPBIA4151ZZ

JPBIA4152ZZ

C : Lock pin engaged D : Most advanced angle

PBIC3684E



EM-60


• Check that it is in the most advanced angle position by seeing if the stopper pin groove (A) and the stop-per pin hole (B) are matched up as shown.

e. Stop applying air pressure and release the camshaft (INT).f. Insert the stopper pin (A) into the stopper pin holes in the cam-

shaft sprocket (INT) and lock in the most advanced angle posi-tion.CAUTION:No load is exerted on the stopper pin (spring reaction, etc.).Since it comes out easily, secure it with tape (B) to preventit from falling out.NOTE:The stopper pin in the figure shows one example of a hexagonalwrench for 2.5 mm (0.098 in) [length of inserted section:approximately15 mm (0.59 in)].

10. Remove the camshaft sprocket (INT):a. Keeping the camshaft hexagonal part (A) in place with the

wrench, loosen mounting the bolts for the camshaft sprocket(INT) (2).

CAUTION:• Never drop stopper pin.• Tape (C) the stopper pin (B) so it does not come out.• Never subject it to impact by dropping.• Never disassemble. [Never loosen the three mounting

bolts (A)].NOTE:While removing the camshaft sprocket (INT), if you have takenout the stopper pin and the lock pin has been rejoined in themost retarded angle, do the following to restore it.

i. Install the camshaft (INT) and tighten the mounting bolts enoughto prevent air from leaking out.CAUTION:The internal lock pin will get damaged, so keep the torqueon the mounting bolts to the minimum required to prevent air from escaping.

ii. Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position.iii. Insert the stopper pin.iv. Remove camshaft sprocket (INT) from the camshaft.

11. Remove camshaft brackets (No. 2 to 5).

JPBIA4153ZZ

1. Camshaft (INT)

JPBIA4154ZZ

PBIC3691E



CAMSHAFT

EM-61


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• Loosen bolts in several steps in the reverse order as shown inthe figure.

NOTE:The camshaft bracket (No. 1) has been already removed.

12. Remove camshaft (EXH).13. Remove camshaft (INT).14. Remove valve lifter.

• Identify installation positions, and store lifters without mixing them up.15. Remove intake valve timing control solenoid valve (1).16. Remove the alternator and bracket, remove the plug (2), and

then remove the oil filter. Refer to EM-56, "Exploded View".

17. Remove exhaust valve timing control solenoid valve.18. Remove the plug on the exhaust valve timing control solenoid valve and the oil filter. Refer to EM-56,

"Exploded View".19. For component inspection after removal, refer to EM-65, "Inspection".

INSTALLATIONCAUTION:Do not reuse O-rings or washers.1. Install oil filter (1) for intake and exhaust valve timing control

solenoid valves.CAUTION:Do not reuse washers.NOTE:The intake side is shown as an example.• The oil filter (1) and washer (2) are assembled to the plug (3),

and then install them in to the cylinder head. Refer to EM-56,"Exploded View".

2. Install intake and exhaust valve timing control solenoid valves.• Insert it straight into the cylinder head.• Tighten bolts.

3. Install valve lifters.• If they are reused, install them in the original positions.

4. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT): NOTE:This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft(INT) and the camshaft sprocket (INT).

A : EXH sideB : INT side

: Engine front

PBIC3686E

PBIC3692E

AWBIA1146GB



E M - 6 2


a. Put the matching marks (A) on a line extending from the knockpin position of camshaft (INT) (1) front surface.• Put the marks on the visible position with the camshaft

sprocket installed as shown. b. Put the matching marks on a line extending from the knock pin

hole (B) position of camshaft sprocket (INT) (2) as shown. • Put the marks on the visible position with it installed to the

camshaft.

5. Put a matching mark for positioning the camshaft (EXH) and the camshaft sprocket (EXH):NOTE:This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft(INT) and the camshaft sprocket (EXH).

a. Put the matching marks (A) on a line extending from the knockpin position of camshaft (EXH) (1) front surface.• Put the marks on the visible position with the camshaft

sprocket installed as shown. b. Put the matching marks on a line extending from the knock pin

hole (B) position of camshaft sprocket (EXH) (2) as shown. • Put the marks on the visible position with it installed to the

camshaft.

6. Install camshaft.

• Note that the camshafts (INT and EXH) have different shapesat the rear.

• Install camshafts to the cylinder head so that knock pins (A) onfront end are positioned as shown.

NOTE:Though camshaft does not stop at the portion as shown for theplacement of cam nose, it is generally accepted camshaft isplaced for the same direction as shown.

PBIC3696E

JPBIA4155ZZ

1 : Camshaft (EXH)2 : Camshaft (INT)A : Identification mark

JPBIA4156ZZ

1 : Camshaft (EXH)2 : Camshaft (INT)

: Upper side

JPBIA4157ZZ



CAMSHAFT

EM-63


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7. Install camshaft brackets (No. 2 to 5) aligning the identificationmarks on upper surface as shown.

• Install so that identification mark can be correctly read whenviewed from the INT side.

8. Tighten mounting bolts of camshaft brackets in the followingsteps, in numerical order as shown.

a. Tighten No. 9 to 11 in numerical order.

b. Tighten No. 1 to 8 in numerical order.

c. Tighten all bolts in numerical order.

d. Tighten all bolts in numerical order.

9. Install the camshaft sprocket (INT and EXH) to the camshaft (INT and EXH): a. Refer to the matching mark (A) added in step 4. Securely align

the knock pin and the pin hole, and then install them.NOTE:The intake side is shown as an example.

10. Tighten the camshaft sprocket mounting bolt (INT and EXH).

CAUTION:Hold the camshaft hexagonal part (A), using a suitable toolto secure the camshaft.


: Engine front

PBIC3703E


: Engine front

Camshaft bracket bolts : 1.96 N·m (0.20 kg-m, 17 in-lb)



Camshaft bracket bolts : 10.4 N·m (1.1 kg-m, 8 ft-lb)

PBIC3686E

PBIC3700E

1 : Camshaft sprocket (EXH)

JPBIA4158ZZ



EM-64


11. Install the camshaft (INT and EXH) to the camshaft sprocket(INT and EXH) (2 and 3) while aligning the matching mark(marked when timing chain is removed) (A) and the pink link (B)of camshaft sprocket (INT and EXH).

• If the positions of knock pin and pin groove are not aligned,move the camshaft (EXH) slightly to correct these positions.

12. Pull out the stopper pin (A), and then apply the tension to thetiming chain by rotating the crankshaft pulley clockwise slightly.

13. Pull out the stopper pin of chain tensioner.14. Install front cover.15. Return the camshaft sprocket (INT) in the most retarded position:a. Remove the stopper pin (A) from the camshaft sprocket (INT).

b. Turn the crankshaft pulley (1) slowly clockwise (A) and returnthe camshaft sprocket (INT) to the most retarded angle position.

1 : Timing chain C : Matching mark (peripheral groove)

JPBIA4159ZZ

1 : Plunger2 : Chain tensionerB : LeverC : Lever holeD : Front cover has been removed for clarity.

PBIC3772E

B : Tape

PBIC3685E

PBIC3704E



CAMSHAFT

EM-65


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• When first turning the crankshaft, the camshaft sprocket (INT)will turn. Once it is turned more, and the vane (camshaft) alsoturns, then it has reached the most retarded angle position.

• The most retarded angle position can be checked by seeing ifthe stopper pin groove (A) is shifted clockwise.

• After spinning the crankshaft slightly in the counterclockwisedirection, you can check the lock pin has joined by seeing ifthe vane (camshaft) and the sprocket move together.

16. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.• Tighten bolts with it completely inserted.

17. Check and adjust valve clearance. Refer to EM-10, "Inspection and Adjustment".18. Installation of the remaining components is in the reverse order of removal.










INSPECTION AFTER REMOVALOil Filter

B : Stopper pin holeC : Most advanced angleD : Lock pin engaged

PBIC3705E












EM-66


• Check that there is no foreign material on the oil filter (1) and checkit for clogging.

• Check the oil filter for damage.• If there is some damage, replace the oil filter, the plug, and the

washer as a set.CAUTION:Do not reuse the washer.

Camshaft Runout1. Put V-block on a precise flat table, and support No. 2 and 5 jour-

nals of camshaft.CAUTION:Never support No. 1 journal (on the side of camshaftsprocket) because it has a different diameter from the otherfour locations.

2. Set a dial indicator vertically to No. 3 journal.3. Turn camshaft to one direction, and measure the camshaft

runout on the dial indicator. (Total indicator reading)

4. If it exceeds the limit, replace camshaft.Camshaft Cam Height1. Measure the camshaft cam height with a micrometer (A).

2. If wear exceeds the limit, replace camshaft.

Camshaft Journal Oil ClearanceCAMSHAFT JOURNAL DIAMETERMeasure the outer diameter of camshaft journal with a micrometer(A).

CAMSHAFT BRACKET INNER DIAMETER• Tighten camshaft bracket bolts to the specified torque. Refer to "INSTALLATION" for the tightening proce-

dure.

PBIC3693E

Standard and Limit: Refer to EM-118, "Camshaft".

PBIC2499E

Standard and LimitIntake

: Refer to EM-118, "Camshaft".Exhaust

Cam wear limit:: Refer to EM-118, "Camshaft".

PBIC3178J

Standard: : Refer to EM-118, "Camshaft".

PBIC3179J



CAMSHAFT

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• Measure inner diameter (b) of camshaft bracket with a bore gauge(A).

CAMSHAFT JOURNAL OIL CLEARANCE• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)

• If it exceeds the limit, replace either or both camshaft and cylinder head.NOTE:Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinderhead. Replace whole cylinder head assembly.

Camshaft End Play1. Install camshaft in cylinder head. Refer to EM-56, "Removal and Installation" for tightening procedure.2. Install a dial indicator (A) in thrust direction on front end of cam-

shaft. Measure the camshaft end play on the dial indicator whencamshaft is moved forward/backward (in direction to axis).

• Measure the following parts if out of the standard.- Dimension “A” for cylinder head No. 1 journal bearing

- Dimension “B” for camshaft thrust

• Refer to the standards above, and then replace camshaft and/or cylinder head.

Camshaft Sprocket Runout1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.

CAUTION:Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameterfrom the other four locations.

Standard : Refer to EM-118, "Camshaft".

JPBIA4192ZZ

Standard and Limit : Refer to EM-118, "Camshaft".

Standard and Limit : Refer to EM-118, "Camshaft".

PBIC3694E

Standard : 4.000 - 4.030 mm (0.1574 - 0.1586 in)

Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)

KBIA3345J



EM-68


2. Measure the camshaft sprocket runout with a dial indicator (A).(Total indicator reading)

• If it exceeds the limit, replace camshaft sprocket.

Valve Lifter Check if surface of valve lifter has any wear or cracks.• If anything above is found, replace valve lifter. Refer to EM-118,

"Camshaft".

Valve Lifter ClearanceVALVE LIFTER OUTER DIAMETER• Measure the outer diameter of valve lifter with a micrometer (A).

VALVE LIFTER HOLE DIAMETERMeasure the diameter of valve lifter hole of cylinder head with aninside micrometer (A).

VALVE LIFTER CLEARANCE• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)

• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diame-ter, replace either or both valve lifter and cylinder head.

INSPECTION AFTER INSTALLATION

Limit : 0.15 mm (0.0059 in)

JPBIA4193ZZ

KBIA0182E


PBIC3185J


PBIC3184J




CAMSHAFT

EM-69


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Inspection of Camshaft Sprocket Oil GrooveCAUTION:• Perform this inspection only when DTC P0011 or P0014 is detected in self-diagnostic results of CON-

SULT and it is directed according to inspection procedure of EC section. Refer to EC-154, "DiagnosisProcedure" (P0011) or EC-158, "Diagnosis Procedure" (P0014).

• Check when engine is cold so as to prevent burns from the splashing engine oil.NOTE:This section provides the inspection method of oil passage of cam sprocket on the intake side. For oil passageon the exhaust side, the inspection procedure must be changed as instructed below:

1. Check engine oil level. Refer to LU-8, "Inspection".2. Perform the following procedure so as to prevent the engine from being unintentionally started while

checking.a. Release the fuel pressure. Refer to EC-126, "Work Procedure".b. Remove intake manifold. Refer to EM-27, "Exploded View".c. Disconnect ignition coil and injector harness connectors. Refer to EM-44, "Exploded View".3. Remove intake valve timing control solenoid valve. Refer to EM-56, "Exploded View".4. Crank engine, and then check that engine oil comes out from

intake valve timing control solenoid valve hole (A). End crankafter checking.

WARNING:Be careful not to touch rotating parts (drive belts, idler pul-ley, and crankshaft pulley, etc.).CAUTION:• Prevent splashing by using a shop cloth to prevent injury

from splashing engine oil and so as to prevent engine oil contamination.• Use a shop cloth to prevent engine oil from being splashed to engine and vehicle. Especially be

careful not to spill engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipeengine oil off immediately if it is splashed.

5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoidvalve oil hole of the cylinder head.• Remove oil filter, and then clean it. Refer to LU-11, "Removal and Installation".• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-6,

"Engine Lubrication System".6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),

and then check each oil groove for clogging.• Clean oil groove if necessary. Refer to LU-6, "Engine Lubrication System".

7. After inspection, installation of components is in the reverse order of removal

· Step 3 : Remove exhaust valve timing control solenoid valve. Refer to EM-56, "Exploded View".

· Step 4 : Crank engine, and then check that engine oil comes out from exhaust valve timing control solenoid valve hole (A). End crank after checking.

·Step 5

Perform the following inspection if engine oil does not come out from exhaust valve timing control solenoid valve oil hole of the cylinder head.• Remove oil filter, and then clean it. Refer to “”.• Clean oil groove between oil strainer and exhaust valve timing control solenoid valve. Refer to

EM-56, "Exploded View".

·Step 6 : Remove components between exhaust valve timing control solenoid valve and camshaft sprocket (EXH), and then check each oil groove for clogging.

1 : Plug

:Engine front

JPBIA4194ZZ



EM-70

< REMOVAL AND INSTALLATION > [HR16DE]OIL SEAL

OIL SEALVALVE OIL SEALVALVE OIL SEAL : Removal and Installation INFOID:0000000007575621

REMOVAL1. Remove camshafts. Refer to EM-56, "Removal and Installation".2. Remove valve lifters. Refer to EM-56, "Removal and Installation".3. Rotate crankshaft, and set piston with valve oil seal to be removed to TDC. This will prevent the valve

from dropping into cylinder.CAUTION:When rotating crankshaft, be careful to avoid scarring front cover with timing chain.

4. Remove valve collet. • Compress valve spring with Tool (A). Remove valve collet with

a magnet hand (B).CAUTION:Be careful not to damage valve lifter holes.

5. Remove valve spring retainer, valve spring and valve spring seat. Refer to EM-75, "Disassembly andAssembly".

6. Remove valve oil seal with Tool (A).

INSTALLATION1. Apply new engine oil to valve oil seal joint surface and seal lip.2. Press in valve oil seal to the height “H” shown with Tool (A).

3. Installation of the remaining components is in the reverse order of removal. FRONT OIL SEAL

Tool number : KV10116200 (J-26336-B): KV10115900 (J-26336-20): KV10109220 ( — )

PBIC3727E

Tool number : KV10107902 (J-38959)

PBIC3728E

Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)

Tool number : KV10115600 (J-38958)

PBIC3211J



OIL SEAL

EM-71


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FRONT OIL SEAL : Removal and Installation INFOID:0000000007575622

REMOVAL1. Remove the following parts.

• Remove wheel and tire. Refer to WT-39, "Adjustment"• Front fender protector (RH). Refer to EXT-26, "Removal and Installation".• Drive belt. Refer to EM-16, "Removal and Installation".• Crankshaft pulley. Refer to EM-47, "Exploded View".

2. Remove front oil seal with a suitable tool.CAUTION:Be careful not to damage front cover and crankshaft.

INSTALLATION1. Apply new engine oil to new front oil seal joint surface and seal lip.2. Install front oil seal so that each seal lip is oriented as shown.

• Press-fit front oil seal using a suitable drift with outer diameter 50 mm (1.97 in) and inner diameter 44mm (1.73 in).CAUTION:• Be careful not to damage front cover and crankshaft.• Press-fit oil seal straight to avoid causing burrs or tilting.

3. Installation of the remaining components is in the reverse order of removal.REAR OIL SEALREAR OIL SEAL : Removal and Installation INFOID:0000000007575623

REMOVAL1. Remove transaxle assembly. Refer to TM-23, "Removal and Installation" (M/T models), TM-249,

"Removal and Installation" (CVT models).2. Remove clutch cover and clutch disk (M/T models). Refer to CL-18, "Removal and Installation".3. Remove flywheel (M/T models) or drive plate (CVT models). Refer to EM-94, "Exploded View".4. Remove rear oil seal with a suitable tool.

CAUTION:Be careful not to damage crankshaft and cylinder block.

INSTALLATION1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.

Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-15, "Recommended Chemical Productsand Sealants".

A : Dust seal lipB : Oil seal lip

: Engine outside

: Engine inside

PBIC3485J



EM-72

< REMOVAL AND INSTALLATION > [HR16DE]OIL SEAL

2. Install rear oil seal so that each seal lip is oriented as shown inthe figure.

• Press-fit rear oil seal with a suitable drift (A) outer diameter113 mm (4.45 in) and inner diameter 90 mm (3.54 in).CAUTION:• Be careful not to damage crankshaft and cylinder block.• Press-fit oil seal straight to avoid causing burrs or tilt-

ing.• Never touch grease applied onto oil seal lip.

• Press in rear oil seal (1) to the position as shown in the figure.

3. Installation of the remaining components is in the reverse order of removal.

A : Dust seal lipB : Oil seal lip

: Engine outside

: Engine inside

PBIC3485J

PBIC3660E

A : Rear end surface of cylinder blockb : 0 - 0.5 mm (0 - 0.020 in)

PBIC3149J



CYLINDER HEAD

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CYLINDER HEADExploded View INFOID:0000000007575624

Cylinder Head Bolts

Valve Components

JPBIA4097ZZ

1. Cylinder head assembly 2. Cylinder head bolt 3. Washer4. Cylinder head gasket A. Refer to EM-74

JPBIA4098GB

1. Spark plug 2. Valve collet 3. Valve spring retainer4. Valve spring 5. Valve spring seat 6. Valve oil seal



EM-74

< REMOVAL AND INSTALLATION > [HR16DE]CYLINDER HEAD


REMOVALNOTE:When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-ing.1. Release fuel pressure. Refer to EC-126, "Work Procedure".2. Remove the following components and related parts.

• Air duct. Refer to EM-25, "Removal and Installation".• Fuel tube and fuel injector. Refer to EM-37, "Exploded View".• Water outlet. Refer to CO-25, "Removal and Installation".• Exhaust manifold. Refer to EM-30, "Exploded View".• Front cover and timing chain. Refer to EM-47, "Exploded View".• Camshaft. Refer to EM-56, "Exploded View".

3. Remove cylinder head loosening bolts in reverse order asshown.

4. Remove cylinder head gasket.

INSTALLATION1. Install new cylinder head gasket.2. Tighten cylinder head bolts in numerical order as shown.

CAUTION:If cylinder head bolts are reused, check their outer diame-ters before installation. Refer to EM-76, "Inspection".

a. Apply new engine oil to threads and seating surfaces of mount-ing bolts.

b. Tighten all bolts.

7. Valve guide (INT) 8. Valve guide (EXH) 9. Valve seat (EXH)10. Valve (EXH) 11. Valve (INT) 12. Valve seat (INT)A. Refer to EM-75


: Engine front

PBIC3732E


: Engine front

Cylinder head bolts : 40.0 N·m (4.1 kg-m, 30 ft-lb)

PBIC3732E



CYLINDER HEAD

EM-75


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c. Turn all bolts 60 degrees clockwise (angle tightening) using Tool(A) in the specified order.CAUTION:Check and confirm the tightening angle by using Tool (A) orprotractor. Avoid judgment by visual inspection without thetool.

d. Completely loosen all bolts.

CAUTION:In this step, loosen bolts in reverse order of that indicated as shown.

e. Tighten all bolts.

f. Turn all bolts 75 degrees clockwise (angle tightening).g. Turn all bolts 75 degrees clockwise again (angle tightening).3. Installation of the remaining components is in the reverse order of removal.

Disassembly and Assembly INFOID:0000000007575626

DISASSEMBLY1. Remove spark plug with a suitable tool.2. Remove valve lifter.

• Identify installation positions, and store lifters without mixing them up.3. Remove valve collet.

• Compress valve spring with Tool (A). Remove valve collet witha magnet tool (B).

CAUTION:Be careful not to damage valve lifter holes.

4. Remove valve spring retainer and valve spring.5. Push valve stem to combustion chamber side, and remove valve.

• Identify installation positions, and store without mixing them up.6. Remove valve oil seal using Tool (A).


PBIC3733E

Cylinder head bolts : 0 N·m (0 kg-m, 0 ft-lb)

Cylinder head bolts : 40.0 N·m (4.1 kg-m, 30 ft-lb)


PBIC3727E

Tool number : KV10107902 (J-38959)

PBIC3728E



EM-76


7. Remove valve spring seat.8. When valve seat must be replaced, refer to EM-76, "Inspection" for removal.9. When valve guide must be replaced, refer to EM-76, "Inspection" for removal.

ASSEMBLY1. Install valve guide if removed. Refer to EM-76, "Inspection".2. Install valve seat if removed. Refer to EM-76, "Inspection".3. Install valve oil seal.

• Install with Tool (A) to match dimension as shown.

4. Install valve spring seat.5. Install valve.

• Install larger diameter to intake side.6. Install valve spring.

NOTE:It can be installed in either direction.

7. Install valve spring retainer.8. Install valve collet.

• Compress valve spring with Tool (A). Install valve collet with amagnet hand (B).CAUTION:Be careful not to damage valve lifter holes.

• Tap valve stem edge lightly with a plastic hammer after instal-lation to check its installed condition.

9. Install valve lifter.10. Install spark plug with a suitable tool.


INSPECTION AFTER REMOVALCylinder Head Bolts Outer Diameter• Cylinder head bolts are tightened by plastic zone tightening

method. Whenever the size difference between “d1” and “d2”exceeds the limit, replace them with a new one.

• If reduction of outer diameter appears in a position other than “d2”,use it as “d2” point.

Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)

Tool number : KV10115600 (J-38958)

PBIC3211J


PBIC3727E

Limit (“d1”–“d2”): 0.15 mm (0.0059 in)

PBIC3717E



CYLINDER HEAD

EM-77


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Cylinder Head DistortionNOTE:When performing this inspection, cylinder block distortion should be also checking. Refer to EM-103, "Inspec-tion".1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.

CAUTION:Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant.

2. At each of several locations on bottom surface of cylinder head,measure the distortion in six directions.

• If it exceeds the limit, replace cylinder head.

INSPECTION AFTER DISASSEMBLYVALVE DIMENSIONS• Check the dimensions of each valve. For the dimensions, refer to EM-120, "Cylinder head".• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to “VALVE SEAT

CONTACT”.VALVE GUIDE CLEARANCE

Valve Stem Diameter• Measure the diameter of valve stem with micrometer (A).

Valve Guide Inner Diameter• Measure the inner diameter of valve guide with bore gauge.

Valve Guide Clearance• (Valve guide clearance) = (Valve guide inner diameter) – (Valve

stem diameter)

• If the calculated value exceeds the limit, replace valve and/or valve guide. Refer to EM-75, "Disassemblyand Assembly".

VALVE GUIDE REPLACEMENTWhen valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.1. To remove valve guide, heat cylinder head to 110 to 130°C (230

to 266°F) by soaking in heated oil.

A : StraightedgeB : Feeler gauge

Limit : Refer to EM-120, "Cylinder head".

PBIC3207J

Standard : Refer to EM-120, "Cylinder head".


Standard and Limit : Refer to EM-120, "Cylinder head".

PBIC3213J

SEM008A



EM-78


2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 USton, 2.0 lmp ton) force] or suitable tool.WARNING:Cylinder head contains heat; when working, wear protectiveequipment to avoid getting burned.

3. Ream cylinder head valve guide hole with a suitable tool.

4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking inheated oil.

5. Using a suitable tool, press valve guide (1) from camshaft sideto dimensions as shown.

WARNING:Cylinder head contains heat; when working, wear protectiveequipment to avoid getting burned.

6. Apply reamer finish to valve guide with a suitable tool.

SEM931C

Valve guide hole diameter (for service parts):Intake and exhaust

: 9.175 - 9.201 mm (0.3612 - 0.3622 in)

SEM932C

SEM008A

Projection “H”: : 11.4 - 11.8 mm (0.448 - 0.464 in)

PBIC3217J

Standard5.000 - 5.018 mm (0.1968 - 0.1975 in)

SEM932C



CYLINDER HEAD

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VALVE SEAT CONTACT• After confirming that the dimensions of valve guides and valves are within the specifications, perform this

procedure.• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve

contact on the surface.• Check if the contact area band is continuous all around the circum-

ference.

• If not, grind to adjust valve fitting and check again. If the contactingsurface still has “NG” conditions (B) even after the recheck,replace valve seat. Refer to EM-75, "Disassembly and Assembly".

VALVE SEAT REPLACEMENTWhen valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess

in cylinder head. Set the machine depth stop to ensure this. Refer to MA-12, "Fluids and Lubricants".CAUTION:Prevent scoring cylinder head by excessive boring.

2. Ream cylinder head recess diameter for service valve seat.

• Be sure to ream in circles concentric to the valve guide center.This will enable valve seat to fit correctly.

3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking inheated oil.

4. Provide valve seats cooled well with dry ice. Press-fit valve seats into cylinder head.WARNING:Cylinder head contains heat; when working, wear protective equipment to avoid getting burned.CAUTION:Avoid directly touching cold valve seats.

A : OK

JPBIA0187ZZ

Oversize [0.5 mm (0.020 in)]Intake : 32.500 - 32.527 mm (1.2795 - 1.2805 in)Exhaust : 26.400 - 26.427 mm (1.0393 - 1.0404 in)

SEM795A

SEM008A



EM-80


5. Using a suitable tool a valve seat grinder, finish valve seat to thespecified dimensions. For dimensions, refer to MA-12, "Fluidsand Lubricants".CAUTION:When using a valve seat cutter, firmly grip the cutter handlewith both hands. Then, press the contacting surface evenlyaround the valve seat to cut in a single attempt. Improperpressure or cutting several times may result in wavy valveseat.

6. Using compound, grind to adjust valve fitting. 7. Check again for normal contact. Refer to "VALVE SEAT CONTACT".VALVE SPRING SQUARENESS• Set a tri-square (A) along the side of valve spring and rotate spring.

Measure the maximum clearance between the top of spring andtri-square.

• If it exceeds the limit, replace valve spring.

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD• Check valve spring pressure with valve spring seat installed at the

specified spring height.CAUTION:Never remove valve spring seat from valve spring.

• If the installation load or load with valve open is out of the stan-dard, replace valve spring (with valve spring seat).








SEM934C

B : Contact

Limit : Refer to EM-120, "Cylinder head".

PBIC3219J


SEM113



CYLINDER HEAD

EM-81


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EM-82

< UNIT REMOVAL AND INSTALLATION > [HR16DE]ENGINE ASSEMBLY

UNIT REMOVAL AND INSTALLATIONENGINE ASSEMBLYExploded View INFOID:0000000007576008

CAUTION:Check that the stud bolt (*2) is tight at the specified torque before tightening the mounting nut (*1)shown in the figure. [Stud bolt (*2) may be loosened after loosening the mounting nut (*1)]


WARNING:• Position the vehicle on a flat and solid surface.• Place chocks at front and back of rear wheels.• Attach proper slingers and bolts described in PARTS CATALOG if engine is not already equipped.CAUTION:• Always be careful to work safely.• Never start working until exhaust system and coolant are cool enough.• If items or work required are not covered by the engine section, refer to the applicable sections.• Always use the support point specified for lifting.

1. Engine mounting (RH) stay 2. Engine mount (RH) stay 3. Engine mounting insulator (RH)4. Rear engine mounting bracket 5. Rear torque rod 6. Engine mounting bracket (LH)7. Engine mounting bracket (LH) 8. Engine mounting insulator (LH) 9. Mass damperA. Front mark B. Transaxle (upper) C. Transaxle (lower)D. M/T models

JSBIA1095GB



ENGINE ASSEMBLY

EM-83

< UNIT REMOVAL AND INSTALLATION > [HR16DE]

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• Use either 2-pole lift type or separate type lift. If board-on type must be used, support the rear axlejacking point with a transmission jack or similar tool before starting work, in preparation for thebackward shift of center of gravity.

• For supporting points for lifting and jacking point at rear axle, refer to GI-30, "2-Pole Lift".NOTE:When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-ing.

REMOVALOutlineRemove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-saxle.Preparation1. Release fuel pressure. Refer to EC-126, "Work Procedure".2. Drain engine coolant from radiator. Refer to CO-8, "Draining Engine Coolant".

CAUTION:• Perform this step when the engine is cold.• Never spill engine coolant on drive belts.

3. Remove the following parts:• Front road wheels and tires (RH and LH).• Front fender protector (RH and LH). Refer to EXT-26, "Exploded View". • Drive belt: Refer to EM-16, "Removal and Installation".• Battery and battery tray. Refer to CHG-23, "Exploded View".• Air duct (inlet), air duct, and air cleaner case assembly. Refer to EM-25, "Removal and Installation".• Radiator hose (upper and lower). Refer to CO-14, "Exploded View".• Exhaust front tube. Refer to EX-5, "Exploded View".

Engine Room LH1. Disconnect all connections of engine harness around the battery, and then temporarily secure the engine

harness into the engine side.CAUTION:Protect connectors against foreign materials during the operation by wrapping in a plastic bag.

2. Disconnect heater hoses. Refer to CO-14, "Exploded View".3. Disconnect fuel feed hose at engine side. Refer to EM-37, "Removal and Installation".4. Disconnect control linkage cable from transaxle. Refer to TM-19, "Removal and Installation" (M/T mod-

els), TM-229, "Removal and Installation" (CVT models).5. Disconnect clutch tube on transaxle side from clutch damper. Refer to CL-14, "Exploded View".Engine Room RH1. Remove alternator. Refer to CHG-23, "Exploded View".2. Disconnect vacuum hose at engine side. 3. Remove EVAP hoses at engine side. 4. Remove air conditioner compressor from the engine with the piping connected. Temporarily position the

air conditioner compressor on the vehicle side with a rope without placing a heavy load on the piping.Vehicle Underbody1. Remove ground cable at transaxle side.2. Remove drive shafts (RH and LH). Refer to FAX-15, "Exploded View".



EM-84

< UNIT REMOVAL AND INSTALLATION > [HR16DE]ENGINE ASSEMBLY

3. Remove rear torque rod (1).

4. Preparation for the separation work of transaxle is as follows:• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-82, "Exploded

View".Removal1. When engine can be hoisted, install engine slinger to cylinder

head front left side (A) and rear right side (B) and support theengine position with a suitable tool.

2. Use a suitable tool (A) to securely support the bottom of theengine and the transaxle assembly.CAUTION:Put a piece of wood or an equivalent as the supporting sur-face and secure in a stable condition.

3. Remove engine mounting insulator (RH) (1).

4. Remove engine mounting through bolt-securing nut (C).

5. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. Observe the followingcautions:CAUTION:• Check that no part interferes with the vehicle side.• Before and during lifting, always check if any harnesses are left connected.• During removal, always be careful to prevent the vehicle from falling off the lift due to changes in

the center of gravity.

2 : Rear engine mounting bracket

: Vehicle front

JSBIA0643ZZ

: Engine front

Slinger (A) bolts : 65.0 N·m (6.6 kg-m, 48 ft-lb)Slinger (B) bolts : 25.0 N·m (2.6 kg-m, 18 ft-lb)

AWBIA1134GB

PBIC3223J

2 : Engine mounting insulator (LH)A : Engine front sideB : Transaxle side

JSBIA1223ZZ



ENGINE ASSEMBLY

EM-85

< UNIT REMOVAL AND INSTALLATION > [HR16DE]

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• If necessary, support the vehicle by setting jack or suitable tool at the rear.Separation1. Remove starter motor. Refer to STR-22, "Exploded View".2. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-23, "Exploded View"

(M/T models), TM-249, "Exploded View" (CVT models).

INSTALLATIONInstallation is in the reverse order of removal.CAUTION:• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-

ing insulator.• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.• When installation directions are specified, install parts according to the direction marks on them,

referring to the figure of components. Refer to EM-82, "Exploded View".Engine Mounting Insulator (RH)• Tighten mounting bolts in the numerical order as shown.

INSPECTION AFTER INSTALLATION• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required








: Vehicle front

JPBIA2809ZZ












EM-86

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]ENGINE STAND SETTING

UNIT DISASSEMBLY AND ASSEMBLYENGINE STAND SETTINGSetting INFOID:0000000007575631

NOTE:The following procedures explain how to disassemble the engine with the engine stand fastened to the bellhousing. Some steps may be different if using a different type of engine stand.1. Install engine to engine stand:a. Remove flywheel or drive plate.

• Secure flywheel (1) or drive plate using tool (A), and removemounting bolts (M/T models).

CAUTION:• Never disassemble flywheel.• Never place flywheel or drive plate with signal plate fac-

ing down.• When handling signal plate, take care not to damage or

scratch it. • Handle signal plate in a manner that prevents it from

becoming magnetized.

b. Lift the engine with a hoist to install it onto a suitable tool.CAUTION:• Use the engine stand that has a load capacity approximately 150 kg (331 lb) or more large

enough for supporting the engine weight. • If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-

tial risk of overturning stand.- Intake manifold. Refer to EM-27, "Exploded View". - Exhaust manifold. Refer to EM-30, "Removal and Installation".- Rocker cover. Refer to EM-44, "Exploded View".NOTE:The figure shows an example of widely used engine stand (A)that can support the mating surface of transaxle with flywheelremoved.CAUTION:Before removing the hanging chains, check the enginestand is stable and there is no risk of overturning.

2. Drain engine oil. Refer to LU-9, "Draining".CAUTION:• Be sure to clean drain plug and install with new drain plug washer.• Do not reuse drain plug washer.

Tool number : KV11105210 (J-44716)

MBIB1382E

PBIC3227J



ENGINE STAND SETTING

EM-87

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]

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3. Drain engine coolant by removing water drain plug (1) frominside of the engine.

Use Genuine Silicone RTV Sealant or equivalent. Refer toGI-15, "Recommended Chemical Products and Sealants".

: Engine front

Water drain plug tightening torque

: Refer to EM-94, "Exploded View".

PBIC3742E



EM-88

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]ENGINE UNIT

ENGINE UNITDisassembly INFOID:0000000007575632

1. Remove intake manifold. Refer to EM-27, "Exploded View".2. Remove exhaust manifold. Refer to EM-30, "Exploded View".3. Remove oil pan (lower). Refer to EM-33, "Exploded View".4. Remove ignition coil, spark plug, and rocker cover. Refer to EM-44, "Exploded View".5. Remove fuel injector and fuel tube. Refer to EM-37, "Exploded View".6. Remove front cover and timing chain. Refer to EM-47, "Exploded View".7. Remove camshaft. Refer to EM-56, "Exploded View".8. Remove cylinder head. Refer to EM-73, "Exploded View".

Assembly INFOID:0000000007575633

Assembly is in the reverse order of disassembly.



OIL PAN (UPPER) AND OIL STRAINER

EM-89


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OIL PAN (UPPER) AND OIL STRAINERExploded View INFOID:0000000007575634


NOTE:The oil strainer is included in the oil pan (upper) and cannot be removed.

REMOVAL1. Remove the oil pan (lower). Refer to EM-33, "Exploded View".

1. Rear oil seal 2. O-ring 3. Oil pan (upper)4. Oil pump chain tensioner (for oil

pump drive chain)5. Oil pump drive chain 6. Crankshaft key

7. Crankshaft sprocket 8. Oil pump sprocket 9. Oil pump10. O-ring 11. O-ring 12. Oil pan drain plug13. Drain plug washer 14. Oil pan (lower) 15. Oil filter16. Connector bolt 17. Oil cooler 18. O-ring19. Relief valve A. Refer to EM-47 B. Refer to LU-11C. Oil pan (lower) side

AWBIA1569ZZ



EM-90

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]OIL PAN (UPPER) AND OIL STRAINER

2. Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to EM-47,"Exploded View".

3. Remove oil pan (upper).a. Loosen oil pan (upper) mounting bolts in the reverse of the order

as shown.

b. Insert a flat-bladed offset screwdriver into the arrow ( ) in thefigure and open up a crack between the oil pan (upper) cylinderblock.

c. Insert the Tool between the oil pan (upper) and cylinder block.Slide Tool by tapping on the side of Tool with a hammer.

CAUTION:• Be careful not to damage the mating surface.• The liquid gasket used at the factory is very strong. Pry only in the areas shown.• Never remove oil pump and oil strainer from oil pan (upper).

4. Remove rear oil seal from crankshaft.

INSTALLATIONCAUTION:Do not reuse O-rings or washers.1. Install the oil pan (upper):a. Use scraper to remove old liquid gasket from mating surfaces.

• Also remove the old liquid gasket from mating surface of cylinder block.• Remove old liquid gasket from the bolt holes and threads.CAUTION:Never scratch or damage the mating surfaces when cleaning off old liquid gasket.

b. Install O-ring to the cylinder block.

: Engine front

JPBIA4199ZZ

: Engine front

Tool number : KV10111100 (J-37228)JPBIA4200ZZ




EM-91


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c. Apply a continuous bead of liquid gasket with the Tool or suitabletool to areas as shown in the figure.Use Genuine Silicone RTV Sealant or equivalent. Refer toGI-15, "Recommended Chemical Products and Sealants".

CAUTION:Attaching should be done within 5 minutes after coating.

d. Tighten bolts in the numerical order as shown.

CAUTION:Install avoiding misalignment of both oil pan gasket and O-ring.• The bolts are different according to the installation position.

Refer to the numbers as shown.

2. Install rear oil seal:CAUTION:• The installation of rear oil seal should be completed within 5 minutes after installing oil pan

(upper).• Never touch oil seal lip.

a. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder blockusing a suitable tool.

b. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Liquid Gasket or equivalent.

1 : Cylinder block2 : Oil pan (upper)A : 2 mm (0.07 in) protruded to outsideB : 2 mm (0.07 in) protruded to rear oil seal mounting sided : 5.5 - 7.5 mm (0.217 - 0.295 in)e : 4.0 - 5.0 mm (0.157 - 0.197 in) diameter

: Engine front side

JSBIA1301ZZ

: Engine front

M8×180 mm (7.09 in) : No. 9, 10M8×25 mm (0.98 in) : No. 4, 7, 8 M8×90 mm (3.54 in) : No. 1, 2, 3, 5, 6

JPBIA4199ZZ



EM-92

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]OIL PAN (UPPER) AND OIL STRAINER

c. Press-fit the rear oil seal using a drift with outer diameter 113mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercialservice tool) (A).

• Press-fit to the dimensions specified as shown in the figure.

CAUTION:• Never touch the grease applied to the oil seal lip.• Be careful not to damage the rear oil seal mounting part

of oil pan (upper) and cylinder block or the crankshaft.• Press-fit straight and check that oil seal does not curl or

tilt.d. After press-fitting the rear oil seal, completely wipe off any liquid

gasket protruding to rear end surface side.3. Installation of the remaining components is in the reverse order of removal. 4. Add the specified oil after waiting for at least 30 minutes. Refer to MA-12, "Fluids and Lubricants".

CAUTION:• The components must be installed within 5 minutes of the liquid gasket application. • Allow 30 minutes for the liquid gasket to set before adding oil to the engine.








PBIC3660E

1 : Rear oil sealA : Rear end surface of cylinder block

PBIC3149J











EM-93


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EM-94

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]CYLINDER BLOCK

CYLINDER BLOCKExploded View INFOID:0000000007575637

1. Crankshaft position sensor cover 2. Crankshaft position sensor (POS) 3. O-ring4. Drain plug 5. Cylinder block 6. Oil level gauge7. Oil level gauge guide 8. O-ring 9. Knock sensor

JPBIA4749GB



CYLINDER BLOCK

EM-95


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Disassembly and Assembly INFOID:0000000007575638

DISASSEMBLYNOTE:The following procedures explain how to disassemble the engine with the engine stand fastened to the bellhousing. Some steps may be different if using a different type of engine stand.1. Remove cylinder head. Refer to EM-73, "Exploded View".2. Remove knock sensor.

CAUTION:Carefully handle knock sensor avoiding shocks.

3. Remove the crankshaft position sensor cover (3), and thencrankshaft position sensor (POS) (2).

CAUTION:• Avoid impacts such as a dropping.• Never disassemble.• Keep sensor away from metal particles.• Never place the sensor in a location where it is exposed to

magnetism.• Do not reuse O-ring.

4. Remove oil pan (upper and lower). Refer to EM-89, "Exploded View".5. Remove piston and connecting rod assembly:

• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer toEM-103, "Inspection".

a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. b. Remove connecting rod cap. c. Using a hammer handle or similar tool, push piston and connect-

ing rod assembly out through the cylinder head side. CAUTION:• Be careful not to damage mating surface with connecting

rod cap.• Be careful not to damage the cylinder wall or crankshaft

pin.

6. Remove connecting rod bearings. CAUTION:Identify original positions for installation, and store the bearings without mixing them up.

10. Oil temperature sensor 11. Oil pressure sensor 12. Oil jet13. Top ring 14. Second ring 15. Oil ring16. Piston 17. Piston pin 18. Connecting rod19. Connecting rod bearing (upper) 20. Main bearing (upper) 21. Thrust bearing22. Crankshaft key 23. Connecting rod bolt 24. Connecting rod cap25. Connecting rod bearing (lower) 26. Main bearing (lower) 27. Crankshaft28. Pilot converter (CVT models) 29. Signal plate 30. Rear oil seal31. Drive plate (CVT models) 32. Reinforce plate (CVT models) 33. Flywheel (M/T models)34. Main bearing cap 35. Main bearing cap bolt A. Refer to EM-95

B. Chamfered : Crankshaft side

1. O-ring4. Cylinder block

: Engine front

JPBIA4202ZZ

KBIA3365J



EM-96


7. Remove piston rings from piston. • Before removing piston rings, check the piston ring side clearance. Refer to EM-103, "Inspection".• Use a suitable tool) (A) as shown.

CAUTION:• When removing piston rings, be careful not to damage

the piston.• Be careful not to damage piston rings by expanding

them excessively.

8. Remove piston from connecting rod.• Use a Tools (A, B, C) and a press to remove the piston pin.

CAUTION:• Do not damage the piston and connecting rod.• Do not reuse piston and piston pin after removing piston

pin from connecting rod. • The connecting rod is reusable.NOTE:The joint between the connecting rod and the piston pin is a press fit.

9. Remove the main bearing cap.• Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-103, "Inspection".

a. Loosen and remove bolts in several steps in reverse of thenumerical order as shown.

NOTE:When removing or installing signal plate, use socket (size T40).

b. Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.

10. Remove crankshaft (2).CAUTION:• Be careful not damage or deform signal plate (1) mounted

on crankshaft.• When setting crankshaft on a flat floor surface, use a

block of wood to avoid interference between signal plateand the floor surface.

• Do not remove signal plate unless it is necessary to doso.

NOTE:When removing or installing signal plate, use socket (size T40).

11. Pull rear oil seal out from rear end of crankshaft.12. Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing caps.

CAUTION:

PBIC3233J

Tool Number A : KV10109730 B : KV10110310 C : ST13030020

PBIC5270J

: Engine front

JPBIA4203ZZ

JPBIA4531ZZ



CYLINDER BLOCK

EM-97


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Identify original installation positions, and store the bearings without mixing them up.13. Remove oil jets.

CAUTION:Insert the dowel pin of oil jet into the cylinder block dowel pin hole to loosen the mounting bolt.

ASSEMBLYCAUTION:Do not reuse O-rings.1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to

remove any foreign material.WARNING:Use goggles to protect your eyes.

2. Install oil jets.3. Install main bearings and thrust bearings:a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.b. Install thrust bearings to the both sides of the No. 3 journal hous-

ing (B) on cylinder block.

• Install thrust bearings with the oil groove (A) facing crankshaftarm (outside).

c. Install the main bearings paying attention to the direction.• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply

engine oil to the back surface, but thoroughly clean it.• When installing, align main bearing to the center position of cylinder block and main bearing cap.• Ensure the oil holes on cylinder block and oil holes (A) on the

main bearings (1) are aligned.NOTE:For assembly, the center position can be visually identified.

• To install the main bearing, obtain a proper fit. Do not allow themain bearing to lie off the cylinder block chamfer.

• To install the main bearing, obtain a proper fit. Do not allow themain bearing to lie off bearing cap chamfer.

4. Install signal plate to crankshaft if removed.a. Set the signal plate (1) with the flange facing toward the counter-

weight side (engine front side) to the crankshaft rear surface.

b. After positioning crankshaft and signal plate with positioningdowel pin, tighten bolt.NOTE:Dowel pin of crankshaft and signal plate is provided as a set foreach.

c. Remove dowel pin.CAUTION:Be sure to remove dowel pin.

5. Install crankshaft to cylinder block.

: Engine front

PBIC3258J

PBIC3746E

A : Dowel pin hole

JPBIA4231ZZ



EM-98


• While turning crankshaft by hand, check that it turns smoothly. CAUTION:Do not install rear oil seal at this time.

6. Install main bearing caps.• Install the main bearing cap while referring to the front mark

(B) and the journal number stamp (A).

NOTE:Main bearing cap cannot be replaced as a single part,because it is machined together with cylinder block.

7. Tighten main bearing cap bolts in numerical order as shown withthe following steps:

a. Apply new engine oil to threads and seat surfaces of the mount-ing bolts.

b. Tighten main bearing cap bolts in numerical order.

c. Turn main bearing cap bolts 60 degrees clockwise (angle tight-ening) in numerical order as shown in the figure.CAUTION:Check and confirm the tightening angle by using the Tool(A) or protractor. Avoid judgment by visual inspection with-out the Tool.

• After installing the main bearing cap bolts, check that crankshaft can be rotated smoothly by hand.• Check crankshaft end play. Refer to EM-103, "Inspection".8. Install piston to connecting rod with the following procedure: a. Set so that the front mark (A) on the piston head and the cylin-

der number (C) are in the position as shown.

NOTE:The symbols without notes are for manufacturing.

: Engine front

JPBIA4204ZZ

: Engine front

Main bearing cap bolts : 32.4 N·m (3.3 kg-m, 24 ft-lb)JPBIA4203ZZ


PBIC3750E

B : Oil holeD : Connecting rod big end grade

PBIC3766E



CYLINDER BLOCK

EM-99


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b. Press-fit the piston pin using the Tools (A, B, C, D, E).

CAUTION:Press-fit the piston so as not to damage it.NOTE:The joint between the connecting rod and the piston pin is apress fit.

• Press-fit the piston pin (2) from piston surface (A) to the depthof 2.35 mm (0.092 in) (b).

• After finishing work, check that the piston (3) moves freely.

9. Using suitable tool (A), install piston rings. CAUTION:• Be careful not to damage piston.• Be careful not to damage piston rings by expanding them

excessively.

• Position each ring with the gap as shown referring to the pis-ton front mark (B).

• Install second ring with the stamped mark (E) facing upward.

Tool number A : KV10109730 B : KV10110310 C : ST13030020 D : KV10114120 E : ST13030030 F : Detail

PBIC5271J

1 : Connecting rod

: Press-fit direction

JPBIA2058ZZ

PBIC3233J

A : Oil ring upper or lower rail gap (either of them)C : Second ring and oil ring spacer gapD : Top ring gap

PBIC3752E



EM-100


10. Install connecting rod bearings to connecting rod and connecting rod cap.• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not

apply engine oil to the back surface, but thoroughly clean it. • Install the bearing in the center position.

NOTE:There is no stopper tab.

• Check that the oil holes on connecting rod and connecting rod bearing are aligned.• Install the connecting rod in the dimension (A) as shown.

NOTE:Install the connecting rod bearing in the center position withthe dimension as shown. For service operation, the centerposition can be checked visually.

11. Install piston and connecting rod assembly to crankshaft. • Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. • Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. • Match the cylinder position with the cylinder number on connecting rod to install. • Using Tool (A) or suitable tool, install piston with the front mark

on the piston head facing the front of the engine. CAUTION:• Be careful not to damage mating surface with connect-

ing rod cap.• Be careful not to damage the cylinder wall or crankshaft

pin.

12. Install connecting rod cap. • Match the stamped cylinder number marks (C) on connecting

rod with those on connecting rod cap to install.

13. Inspect outer diameter of connecting rod bolts. Refer to EM-103, "Inspection".14. Tighten connecting rod bolt:a. Apply new engine oil to the threads and seats of connecting rod bolts.

Stamped mark:Top ring : 1RSecond ring : 2R

1 : Connecting rod2 : Connecting rod bearing (upper)3 : Connecting rod bearing (lower)4 : Connecting rod capA : 1.7 - 2.1 mm (0.067 - 0.083 in)

: Engine front

PBIC4169E

Tool number : EM03470000

PBIC3765E

A : Front markB : Oil holeD : Connecting rod big end grade

PBIC3766E



CYLINDER BLOCK

EM-101


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b. Tighten connecting rod bolts in several steps.

c. Completely loosen connecting rod bolts.

d. Tighten connecting rod bolts in several steps.

e. Then turn all connecting rod bolts 60 degrees clockwise (angle tightening).CAUTION:Check and confirm the tightening angle by using the Tool (A) or protractor. Avoid judgement byvisual inspection without the Tool.

• After tightening connecting rod bolt, check that crankshaft rotates smoothly. • Check the connecting rod side clearance. Refer to EM-103, "Inspection".15. Install oil pan (upper). Refer to EM-89, "Exploded View".

NOTE:Install the rear oil seal after installing the oil pan (upper).

16. Install rear oil seal. Refer to EM-71, "REAR OIL SEAL : Removal and Installation".17. Install flywheel (M/T models) or drive plate (CVT models).

M/T models• Secure crankshaft with a stopper plate (A) and tighten mount-

ing bolts crosswise over several times.

CVT models

Connecting rod bolts : 27.4 N·m (2.8 kg-m, 20 ft-lb)

Connecting rod bolts : 0 N·m (0 kg-m, 0 ft-lb)

Connecting rod bolts : 19.6 N·m (2.0 kg-m, 14 ft-lb)


PBIC3753E

1 :Flywheel

Tool number : KV11105210 (J-44716)

MBIB1382E



EM-102


• Secure crankshaft with a stopper plate (A) and tighten mount-ing bolts crosswise over several times.

CAUTION:Be careful not to damage or scratch and contact surface for clutch disc of flywheel.

18. Install knock sensor (1).

• Install connectors so that they are positioned toward the rearof the engine.

CAUTION:• Never tighten mounting bolt while holding the connector. • If any impact by dropping is applied to knock sensor,

replace it with a new one.NOTE:• Check that there is no foreign material on the cylinder block

mating surface and the back surface of knock sensor. • Check that knock sensor does not interfere with other parts.

19. Install crankshaft position sensor (POS) (2) using a new O-ring(1) and then install the crankshaft position sensor cover (3) onthe cylinder block (4).• Tighten bolts with sensor inserted completely.

CAUTION:• Avoid impacts such as a dropping.• Never disassemble.• Keep sensor away from metal particles.• Never place the sensor in a location where it is exposed to

magnetism.• Do not reuse O-ring.

20. For the oil level gauge guide (1), secure in position (B) shown inthe figure to the water inlet clip (A) after inserting to the cylinderblock side.

21. Assembly of the remaining components is in the reverse order of disassembly.

1 :Drive plate

Tool number : KV11105210 (J-44716)

PBIC3226J

: Engine front

: Engine front

PBIC3754E

JPBIA4202ZZ

PBIC3755E



CYLINDER BLOCK

EM-103


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CRANKSHAFT END PLAY• Measure the clearance between thrust bearings and crankshaft

arm when crankshaft is moved fully forward or backward with asuitable tool (A).

• If the measured value exceeds the limit, replace thrust bearings,and measure again. If it still exceeds the limit, replace crankshaftalso.

CONNECTING ROD SIDE CLEARANCE• Measure the side clearance between connecting rod and crank-

shaft arm with a suitable tool (A).

• If the measured value exceeds the limit, replace connecting rod,and measure again. If it still exceeds the limit, replace crankshaftalso.

PISTON TO PISTON PIN OIL CLEARANCEPiston Pin Hole Diameter Measure the inner diameter of piston pin hole with an suitable tool(A).

Piston Pin Outer Diameter Measure the outer diameter of piston pin with a suitable tool (A).

Piston to Piston Pin Oil Clearance(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

Standard and Limit : Refer to EM-122, "Cylinder Block".

PBIC3762E


PBIC3763E

Standard : Refer to EM-122, "Cylinder Block".

PBIC3265J


PBIC3266J




EM-104


• If oil clearance is out of the standard, replace piston and piston pin assembly. • When replacing piston and piston pin assembly. Refer to EM-95, "Disassembly and Assembly".

NOTE:• Piston is available together with piston pin as assembly.• Piston pin (piston pin hole) grade is provided only for the parts installed at the factory. For service parts, no

grades can be selected. Only grade “0” is available.

PISTON RING SIDE CLEARANCE• Measure the side clearance of piston ring and piston ring groove

with a suitable tool (A).

• If the measured value exceeds the limit, replace piston ring, andmeasure again. If it still exceeds the limit, replace piston also.

PISTON RING END GAP• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE

CLEARANCE”.• Lubricate piston (1) and piston ring (2) with new engine oil and

then insert (A) piston ring until middle of cylinder (B) with piston,and measure piston ring end gap with a feeler gauge (C).

• If the measured value exceeds the limit, replace piston ring, andmeasure again. If it still exceeds the limit, replace cylinder block.

CONNECTING ROD BEND AND TORSION• Check with a connecting rod aligner.

• If it exceeds the limit, replace connecting rod assembly.

CONNECTING ROD BIG END DIAMETER


PBIC3280J


PBIC3267J

A : BendB : TorsionC : Feeler gauge

Limit : Refer to EM-122, "Cylinder Block".

PBIC3268J



CYLINDER BLOCK

EM-105


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• Install connecting rod cap (1) without connecting rod bearinginstalled, and tightening connecting rod cap bolts to the specifiedtorque. Refer to EM-94, "Exploded View".

• Measure the inner diameter (B) of connecting rod big end with asuitable tool.

• If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCEConnecting Rod Bushing Inner DiameterMeasure the inner diameter of connecting rod bushing with a suit-able tool (A).

Piston Pin Outer DiameterMeasure the outer diameter of piston pin with a micrometer (A).

Connecting Rod Bushing Oil Clearance(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-ter)

• If the measured value is out of the standard range, replace connecting rod assembly and/or piston and pis-ton pin assembly.

• If replacing piston and piston pin assembly. Refer to EM-122, "Cylinder Block".• If replacing connecting rod assembly. Refer to EM-126, "Connecting Rod Bearing".

CYLINDER BLOCK TOP SURFACE DISTORTION• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or

other contamination. CAUTION:Be careful not to allow gasket particles to enter engine oil or engine coolant passages.

2 : Connecting rodA : ExampleB : Measuring direction of inner diameter

Standard : Refer to EM-122, "Cylinder Block". PBIC3269J

Inner diameter (Standard)

: Refer to EM-122, "Cylinder Block".

JPBIA0223ZZ

Outer diameter (Standard)


JPBIA0218ZZ

Oil clearance (Standard and Limit)




EM-106


• Measure the distortion on the cylinder block upper face at differentpoints in six directions with a suitable tool (A) and (B).

• If it exceeds the limit, replace cylinder block.

MAIN BEARING HOUSING INNER DIAMETER• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the

specified torque. Refer to EM-95, "Disassembly and Assembly".• Measure the inner diameter of main bearing housing with a suitable tool. • Measure the position shown [5 mm (0.20 in)] backward from main

bearing housing front side in the 2 directions as shown. Thesmaller one is the measured value.

• If out of the standard, replace cylinder block and main bearingcaps assembly. NOTE:Main bearing caps cannot be replaced individually, because they are machined together with cylinder block.

PISTON TO CYLINDER BORE CLEARANCECylinder Bore Inner Diameter• Using a suitable tool, measure the cylinder bore for wear, out-of-

round and taper at six different points on each cylinder. [(A) and (B)directions at (C), (D), and (E)] [(A) is in longitudinal direction ofengine]

NOTE:When determining cylinder bore grade, measure the cylinder bore(B) direction at (D) position.

• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,replace cylinder block. NOTE:Oversize piston is not available.

Limit : Refer to EM-122, "Cylinder Block".

JPBIA0224ZZ

1 : Cylinder block2 : Main bearing cap

: Engine front

Standard : Refer to EM-122, "Cylinder Block".PBIC4005E

f : 10 mm (0.39 in)g : 60 mm (2.36 in)h : 124 mm (4.88 in)

Standard:Cylinder bore inner diameter


Limit:Out-of-round [Difference between (A) and (B)]Taper [Difference between (C) and (E)]


JPBIA2059ZZ



CYLINDER BLOCK

EM-107


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Piston Skirt DiameterMeasure the outer diameter of piston skirt with a suitable tool (A).

Piston to Cylinder Bore ClearanceCalculate by piston skirt diameter and cylinder bore inner diameter[direction (B), position (D)].

(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame-ter)

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-122, "Cylin-der Block".

CRANKSHAFT MAIN JOURNAL DIAMETER• Measure the outer diameter of crankshaft main journals with a suit-

able tool (A).

• If out of the standard, measure the main bearing oil clearance.Then use undersize bearing. Refer to EM-125, "Main Bearing".

CRANKSHAFT PIN JOURNAL DIAMETER • Measure the outer diameter of crankshaft pin journal with a suitable tool.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Referto EM-126, "Connecting Rod Bearing".

OUT-OF-ROUND AND TAPER OF CRANKSHAFT


PBIC3272J

A : Direction AC : Position CE : Position Ef : 10 mm (0.39 in)g : 60 mm (2.36 in)h : 124 mm (4.88 in)


JPBIA2059ZZ


PBIC3457J




EM-108


• Measure the dimensions at four different points as shown on eachmain journal and pin journal with a suitable tool.

• Out-of-round is indicated by the difference in dimensions between(a) and (b) at (c) and (d).

• Taper is indicated by the difference in dimension between (c) and(d) at (a) and (b).

• If the measured value exceeds the limit, correct or replace crankshaft.• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select

main bearing and/or connecting rod bearing. Refer to EM-126, "Connecting Rod Bearing" and/or EM-125,"Main Bearing".

CRANKSHAFT RUNOUT • Place a V-block on a precise flat table to support the journals on both ends of the crankshaft.• Place a suitable tool (A) straight up on the No. 3 journal. • While rotating crankshaft, read the movement of the pointer on the

suitable tool. (Total indicator reading)

• If it exceeds the limit, replace crankshaft.

CONNECTING ROD BEARING OIL CLEARANCEMethod by Calculation• Install connecting rod bearings (2) to connecting rod (3) and con-

necting rod cap (1), and tighten connecting rod cap bolts to thespecified torque. Refer to EM-95, "Disassembly and Assembly".

• Measure the inner diameter of connecting rod bearing with a suit-able tool.(Bearing oil clearance) = (Connecting rod bearing inner diameter)– (Crankshaft pin journal diameter)

• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big enddiameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-126,"Connecting Rod Bearing".

Method of Using Plastigage• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. • Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil

holes.• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-

fied torque. Refer to EM-95, "Disassembly and Assembly".CAUTION:Never rotate crankshaft.

Limit:Out-of-round [Difference between (a) and (b)]Taper [Difference between (c) and (d)]

: Refer to EM-122, "Cylinder Block".JPBIA0229ZZ


PBIC3458J

A : ExampleB : Inner diameter measuring direction

Standard and Limit : Refer to EM-126, "Connecting Rod Bearing".PBIC3275J



CYLINDER BLOCK

EM-109


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• Remove connecting rod cap and bearing, and using the scale (A)on the plastigage bag, measure the plastigage width. NOTE:The procedure when the measured value exceeds the limit issame as that described in the “Method by Calculation”.

MAIN BEARING OIL CLEARANCEMethod by Calculation• Install main bearings (3) to cylinder block (1) and main bearing cap

(2), and tighten main bearing cap mounting bolts to the specifiedtorque. Refer to EM-95, "Disassembly and Assembly".

• Measure the inner diameter (B) of main bearing (3) with a suitabletool.

(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-shaft main journal diameter)

• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter andcrankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-125, "Main Bearing".

Method of Using Plastigage• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. • Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil

holes.• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to

the specified torque. Refer to EM-95, "Disassembly and Assembly". CAUTION:Never rotate crankshaft.

• Remove main bearing cap and bearings, and using the scale (A)on the plastigage bag, measure the plastigage width. NOTE:The procedure when the measured value exceeds the limit issame as that described in the “Method by Calculation”.

MAIN BEARING CRUSH HEIGHT

PBIC3276J

A : ExampleB : Inner diameter measuring direction

Standard and Limit : Refer to EM-125, "Main Bearing".PBIC3277J

PBIC3278J



EM-110


• When main bearing cap is removed after being tightened to thespecified torque with main bearings (1) installed, the tip end ofbearing must protrude (B). Refer to EM-95, "Disassembly andAssembly".

• If the standard is not met, replace main bearings.

CONNECTING ROD BEARING CRUSH HEIGHT• When connecting rod cap is removed after being tightened to the

specified torque with connecting rod bearings (1) installed, the tipend of bearing must protrude (B). Refer to EM-95, "Disassemblyand Assembly".

• If the standard is not met, replace connecting rod bearings.

MAIN BEARING CAP BOLT OUTER DIAMETER • Measure the outer diameters (d1) and (d2) at two positions as

shown.

• If reduction appears in places other than (B) range, regard it as(d2).

• If it exceeds the limit (a large difference in dimensions), replacemain bearing cap mounting bolt with a new one.

CONNECTING ROD CAP BOLT OUTER DIAMETER • Measure the outer diameter (d) at position as shown.• If reduction appears in a position other than (d), regard it as (d).

• When (d) is less than the limit (when it becomes thinner), replaceconnecting rod cap bolt with a new one.

FLYWHEEL DEFLECTION (M/T models)

A : Example

Standard : There must be crush height.

PBIC3279J

A : Example

Standard : There must be crush height.

PBIC3279J

A : (d1) measuring positionB : (d2) measuring position

Limit [(d1) – (d2)]: 0.2 mm (0.0078 in)

PBIC4015E

Limit: 7.75 mm (0.3051 in)

PBIC4016E



CYLINDER BLOCK

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• Measure the deflection of flywheel contact surface to torque with asuitable tool (A).

• Measure the deflection at 210 mm (8.27 in) diameter.

• If measured value is out of the standard, replace flywheel.• If a trace of burn or discoloration is found on the surface, clean it

with sandpaper.CAUTION:When measuring, keep magnetic fields (such as dial indicatorstand) away from signal plate of the rear end of crankshaft.

Limit : 0.45 mm (0.0177 in) or less.

PBIC4006E



EM-112

< UNIT DISASSEMBLY AND ASSEMBLY > [HR16DE]HOW TO SELECT PISTON AND BEARING

HOW TO SELECT PISTON AND BEARINGDescription INFOID:0000000007575640

• The identification grade stamped on each part is the grade for the dimension measured in new condition.This grade cannot apply to reused parts.

• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing themeasurement with the values of each selection table.

• For details of the measurement method of each part, the reuse standards and the selection method of theselective fitting parts, refer to the text for the appropriate part.

Connecting Rod Bearing INFOID:0000000007575641

WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED1. Apply connecting rod big end diameter grade stamped (C) on

connecting rod side face to the row in the “Connecting RodBearing Selection Table”.

2. Apply crankshaft pin journal diameter grade stamped on crank-shaft front side to the column in the “Connecting Rod BearingSelection Table”.

3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing SelectionTable”.

4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.

WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-

vidually. Refer to EM-103, "Inspection".

Selection points Selection parts Selection items Selection methods

Between cylinder block and crankshaft Main bearing Main bearing grade (bearing

thickness)

Determined by match of cylin-der block bearing housing grade (inner diameter of hous-ing) and crankshaft journal grade (outer diameter of jour-nal)

Between crankshaft and con-necting rod Connecting rod bearing Connecting rod bearing grade

(bearing thickness)

Combining service grades for connecting rod big end diame-ter and crankshaft pin outer di-ameter determine connecting rod bearing selection.

A : Oil holeB : Cylinder numberD : Front mark

PBIC3756E

A : Main journal diameter grade (No. 1 to 5 from left)B : Crankshaft pin journal diameter grade (No. 1 to 4 from left)

PBIC3757E



HOW TO SELECT PISTON AND BEARING

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2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection

Table”.4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.Connecting Rod Bearing Selection Table

Connecting Rod Bearing Grade Table

Undersize Bearings Usage Guide• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod

bearings, use undersize (US) bearings.• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing

installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION:

JPBIA4823GB

Connecting Rod Bearing Grade Table : Refer to EM-126, "Connecting Rod Bearing".



EM-114


In grinding crankshaft pin to use undersize bearings, keep thefillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)].

Main Bearing INFOID:0000000007575642

HOW TO SELECT MAIN BEARINGWhen New Cylinder Block and Crankshaft Are Used1. “Main Bearing Selection Table” rows correspond to main bearing

housing grade on left side of cylinder block.

• If there is a corrected stamp mark (B) on cylinder block, use itas a correct reference.

2. Apply main journal diameter grade stamped on crankshaft frontside to column in the “Main Bearing Selection Table”.

3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.

NOTE:Service part is available as a set of both upper and lower.

When Cylinder Block and Crankshaft Are Reused1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main

journal diameter individually. Refer to EM-103, "Inspection".2. Apply the measured dimension to the “Main Bearing Selection Table”.3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.

Bearing undersize table:Refer to EM-126, "Connecting Rod Bearing".

PBIC3263J

A : Basic stamp mark

: Engine front

PBIC3760E

A : Main journal diameter grade (No. 1 to 5 from left) B : Crankshaft pin journal diameter grade (No. 1 to 4 from left)

PBIC3757E



HOW TO SELECT PISTON AND BEARING

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Main Bearing Selection Table

Main Bearing Grade Table

Use Undersize Bearing Usage Guide• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-

size (US) bearing. • When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and

grind main journal so that the main bearing oil clearance satisfies the standard.CAUTION:

PBIC3759E

Main Bearing Grade Table : Refer to EM-125, "Main Bearing".



EM-116


In grinding crankshaft main journal to use undersize bearings,keep fillet (A) [0.8 - 1.2 mm (0.031 - 0.047 in)].

Bearing undersize table: Refer to EM-125, "Main Bear-ing".

PBIC3263J



SERVICE DATA AND SPECIFICATIONS (SDS)

EM-117

< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]

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SERVICE DATA AND SPECIFICATIONS (SDS)SERVICE DATA AND SPECIFICATIONS (SDS)General Specification INFOID:0000000007575643

GENERAL SPECIFICATIONS

Valve TimingUnit: degree

( ): Valve timing control “ON”

Drive Belt INFOID:0000000007575644

DRIVE BELTBelt Deflection

*: When engine is cold.

Engine type HR16DE

Cylinder arrangement In-line 4

Displacement cm3 (cu in) 1,598 (97.51)

Bore and stroke mm (in) 78.0× 83.6 (3.071 ×3.291)

Valve arrangement DOHC

Firing order 1-3-4-2

Number of piston ringsCompression 2

Oil 1

Compression ratio 9.8

Compression pressure kPa (kg/cm2, psi) / 200 rpm

Standard 1,510 (15.4, 219)

Minimum 1,270 (12.95, 184)

Differential limit between cylinders 100 (1.0, 14.5)

Valve timing: Intake valve: Exhaust valve

a b c d e f

216 228 11 (−27)ATDC

59 (-21)ABDC

-1 (49)ATDC

37 (-13)BBDC

JPBIA4228ZZ

Location

Deflection adjustment * Unit: mm (in)

Used beltNew belt

Limit After adjusted

Drive beltWith A/C 10 (0.39) 4.9 - 5.2 (0.19 - 0.20) 4.1 - 4.4 (0.16 - 0.17)

Without A/C 9.1 (0.36) 4.3 - 4.7 (0.17 - 0.19) 3.7 - 3.9 (0.14 - 0.15)

Applied pushing force 98 N (10 kg-f, 22 lb-f)



EM-118

< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]SERVICE DATA AND SPECIFICATIONS (SDS)

Belt Tension and Frequency

*: When engine is cold.

Spark Plug INFOID:0000000007575645

SPARK PLUG (PLATINUM-TIPPED TYPE)

*: Always check with the Parts Department for the latest parts information.

Exhaust Manifold INFOID:0000000007575646

EXHAUST MANIFOLDUnit: mm (in)

Camshaft INFOID:0000000007575647

CAMSHAFTUnit: mm (in)

Location

Tension adjustment * Unit: N (kg-f, lb-f) Frequency adjustment * Unit: Hz

Used beltNew belt

Used beltNew belt

Limit After adjusted Limit After adjusted

Drive beltWith A/C

350 (35.7, 78.7)

881 - 951 (89.8 - 97.0, 198.1 - 213.8)

1070 - 1138 (109.1 - 116.0, 240.6 - 255.8)

145.5 230.5 - 239.5 254 - 262

Without A/C876 - 964 (89.3 - 98.3, 196.9 - 216.7)

1064 - 1152 (108.5 - 117.5, 239.2 - 259.0)

162 256.5 - 268.5 282.5 - 293.5

Make NGK

Standard type* PLZKAR6A-11

Gap (nominal) 1.1 mm (0.043 in)

Items Limit

Surface distortion 0.3 (0.012)

Items Standard Limit

Camshaft runout [TIR*] 0.02 (0.0008) 0.1 (0.0039)

Camshaft cam height “A”Intake 41.705 - 41.895 (1.6419 - 1.6494) 41.505 (1.6341)

Exhaust 40.915 - 41.105 (1.6108 - 1.6183) 40.715 (1.6029)

Camshaft journal outer diameterNo. 1 27.935 - 27.955 (1.0998 - 1.1006) —

No. 2, 3, 4, 5 24.950 - 24.970 (0.9822 - 0.9830) —

Camshaft bracket inner diameterNo. 1 28.000 - 28.021 (1.1024 - 1.1032) —

No. 2, 3, 4, 5 25.000 - 25.021 (0.9842 - 0.9850) —

SEM671




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*: Total indicator reading

VALVE LIFTERUnit: mm (in)

VALVE CLEARANCEUnit: mm (in)

1:Approximately 20°C (68°F)2:Approximately 80°C (176°F)

AVAILABLE VALVE LIFTERUnit: mm (in)

Camshaft journal oil clearanceNo. 1 0.045 - 0.086 (0.0018 - 0.0034) —

No. 2, 3, 4, 5 0.030 - 0.071 (0.0011 - 0.0027) —

Camshaft end play 0.075 - 0.153 (0.0029 - 0.0060) 0.2 (0.0078)

Camshaft sprocket runout [TIR*] — 0.1 (0.0039)


Items Standard

Valve lifter outer diameter 29.977 - 29.987 (1.1801 - 1.1805)

Valve lifter hole diameter 30.000 - 30.021 (1.1811 - 1.1819)

Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)

Cold1 Hot 2

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)

Exhaust 0.29 - 0.37 (0.011 - 0.014) 0.308 - 0.432 (0.012 - 0.017)

Identification mark (A) Thickness (B)

300 3.00 (0.1181)

302 3.02 (0.1188)

304 3.04 (0.1196)

306 3.06 (0.1204)

308 3.08 (0.1212)

310 3.10 (0.1220)

312 3.12 (0.1228)

314 3.14 (0.1236)

316 3.16 (0.1244)

318 3.18 (0.1251)

320 3.20 (0.1259)

322 3.22 (0.1267)

324 3.24 (0.1275)

JPBIA0170ZZ



EM-120


Cylinder head INFOID:0000000007575648

CYLINDER HEADUnit: mm (in)

VALVE DIMENSIONSUnit: mm (in)

326 3.26 (0.1283)

328 3.28 (0.1291)

330 3.30 (0.1299)

332 3.32 (0.1307)

334 3.34 (0.1314)

336 3.36 (0.1322)

338 3.38 (0.1330)

340 3.40 (0.1338)

342 3.42 (0.1346)

344 3.44 (0.1354)

346 3.46 (0.1362)

348 3.48 (0.1370)

350 3.50 (0.1377)

Identification mark (A) Thickness (B)

Items Limit

Head surface distortion 0.1 (0.004)

Valve head diameter “D”Intake 31.6 - 31.9 (1.244 - 1.256)

Exhaust 25.3 - 25.6 (0.996 - 1.007)

Valve length “a”Intake 101.73 (4.01)

Exhaust 102.49 (4.04)

“b”Intake 1.0 (0.0393)

Exhaust 1.0 (0.0393)

“c”Intake 2.1 - 2.8 (0.0826 - 0.1102)

Exhaust 2.3 - 3.0 (0.0905 - 0.1181)

“c′”Intake 3.0 (0.1181)

Exhaust –

“d ”Intake 4.965 - 4.980 (0.1954 - 0.1960)

Exhaust 4.955 - 4.970 (0.1950 - 0.1956)

Valve seat angle “α”Intake

45°15′ - 45°45′Exhaust

PBIC3878E




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VALVE GUIDEUnit: mm (in)

VALVE SEATUnit: mm (in)

Items Standard part Service part

Valve guideOuter diameter 9.023 - 9.034 (0.3552 - 0.3556) 9.223 - 9.234 (0.3631 - 0.3635)

Inner diameter (Finished size) 5.000 - 5.018 (0.1968 - 0.1975)

Cylinder head valve guide hole diameter 8.975 - 9.001 (0.3533 - 0.3544) 9.175 - 9.201 (0.3612 - 0.3622)

Interference fit of valve guide 0.022 - 0.059 (0.0009 - 0.0023)


Valve guide clearanceIntake 0.020 - 0.053 (0.0008 - 0.0021) 0.1 (0.004)

Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.1 (0.004)

Projection length “L” 11.4 - 11.8 (0.448 - 0.464)

PBIC0184E

Items Standard Oversize [0.5 (0.02)] (Service)

Cylinder head seat recess diameter “D”Intake 32.000 - 32.027 (1.2598 - 1.2609) 32.500 - 32.527 (1.2795 - 1.2806)

Exhaust 25.900 - 25.927 (1.0197 - 1.0207) 26.400 - 26.427 (1.0394 - 1.0404)

Valve seat outer diameter “d”Intake 32.108 - 32.124 (1.2641 - 1.2647) 32.608 - 32.624 (1.2838 - 1.2844)

Exhaust 25.991 - 26.007 (1.0233 - 1.0239) 26.491 - 26.507 (1.0430 - 1.0436)

Valve seat interference fitIntake 0.081 - 0.124 (0.0032 - 0.0049)

Exhaust 0.064 - 0.107 (0.0025 - 0.0042)

Diameter “d1”*1Intake 29.6 (1.165)

Exhaust 23.0 (0.905)

Diameter “d2”*2Intake 31.2 - 31.4 (1.228 - 1.236)

Exhaust 24.9 - 25.1 (0.980 - 0.988)

Angle “α1”Intake 60°

Exhaust 45°

PBIC2745E



EM-122


*1: Diameter made by intersection point of conic angles α1 and α2

*2: Diameter made by intersection point of conic angles α2 and α3

*3: Machining data

VALVE SPRING

Cylinder Block INFOID:0000000007575649

CYLINDER BLOCKUnit: mm (in)

Angle “α2”Intake 88°45′ - 90°15′

Exhaust 88°45′ - 90°15′

Angle “α3”Intake 120°

Exhaust 120°

Contacting width “W”*3Intake 1.05 - 1.35 (0.0413 - 0.0531)

Exhaust 1.15 - 1.55 (0.0453 - 0.0610)

Height “h”Intake 4.7 (0.185) 4.15 (0.163)

Exhaust 6.0 (0.236) 5.43 (0.213)

Depth “H”Intake 4.7 (0.185)

Exhaust 6.0 (0.236)

Free height 46.73 mm (1.8398 in)

Installation height 32.40 mm (1.2755 in)

Installation load 136 - 154 N (13.9 - 15.7 kg, 31 - 35 lb)

Height during valve open 23.96 mm (0.9433 in)

Load with valve open 242 - 272 N (24.7 - 27.7 kg, 54 - 61 lb)

Surface distortion Limit 0.1 (0.004)

Cylinder bore Inner diameter Standard 78.000 - 78.015 (3.0708 - 3.0714)

Wear limit —

Out-of-round (Difference between “X” and “Y”)Limit

0.015 (0.0006)

Taper (Difference between “A” and “C”) 0.010 (0.0004)

PBIC3924E




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* : Always check with the Parts Department for the latest parts information.

AVAILABLE PISTONUnit: mm (in)

PISTON RINGUnit: mm (in)

PISTON PINUnit: mm (in)

Cylinder block main bearing housing inner diameter grade*

Grade No. AGrade No. BGrade No. CGrade No. DGrade No. EGrade No. FGrade No. GGrade No. HGrade No. JGrade No. KGrade No. LGrade No. MGrade No. NGrade No. PGrade No. RGrade No. SGrade No. TGrade No. UGrade No. VGrade No. W

51.997 - 51.998 (2.0471 - 2.0472)51.998 - 51.999 (2.0472 - 2.0472)51.999 - 52.000 (2.0472 - 2.0472)52.000 - 52.001 (2.0472 - 2.0472)52.001 - 52.002 (2.0473 - 2.0473)52.002 - 52.003 (2.0473 - 2.0473)52.003 - 52.004 (2.0474 - 2.0474)52.004 - 52.005 (2.0474 - 2.0474)52.005 - 52.006 (2.0474 - 2.0474)52.006 - 52.007 (2.0475 - 2.0475)52.007 - 52.008 (2.0475 - 2.0475)52.008 - 52.009 (2.0476 - 2.0476)52.009 - 52.010 (2.0476 - 2.0476)52.010 - 52.011 (2.0476 - 2.0476)52.011 - 52.012 (2.0477 - 2.0477)52.012 - 52.013 (2.0477 - 2.0477)52.013 - 52.014 (2.0478 - 2.0478)52.014 - 52.015 (2.0478 - 2.0478)52.015 - 52.016 (2.0478 - 2.0478)52.016 - 52.017 (2.0479 - 2.0479)

Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)

Piston skirt diameter “A” 77.965 - 77.980 (3.0694 - 3.0700)

Piston height “H” dimension 37.1 (1.460)

Piston pin hole diameter 19.006 - 19.012 (0.7482 - 0.7485)

Piston to cylinder bore clearance 0.020 - 0.050 (0.0007 - 0.0019)

PBIC0188E


Side clearance

Top 0.040 - 0.080 (0.0015 - 0.0031) 0.11 (0.0043)

2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)

Oil (rail ring) 0.045 - 0.125 (0.0017 - 0.0049) —

End gap

Top 0.20 - 0.30 (0.0078 - 0.0118) 0.50 (0.0196)

2nd 0.35 - 0.50 (0.0137 - 0.0196) 0.66 (0.0259)

Oil (rail ring) 0.20 - 0.45 (0.0079 - 0.0177) 0.77 (0.0303)

Piston pin outer diameter 18.996 - 19.002 (0.7478 - 0.7481)

Piston to piston pin oil clearance Standard 0.008 - 0.012 (0.0003 - 0.0004)

Connecting rod bushing oil clearance Standard –0.018 to –0.044 (–0.0007 to –0.0017)



EM-124


CONNECTING RODUnit: mm (in)

*1 : After installing in connecting rod

*2 : Always check with the Parts Department for the latest parts information.

CRANKSHAFTUnit: mm (in)

Center distance 129.84 - 129.94 (5.1118 - 5.1157)

Bend [per 100 (3.94)] Limit 0.15 (0.0059)

Torsion [per 100 (3.94)] Limit 0.30 (0.0118)

Connecting rod bushing inner diameter*1 18.958 - 18.978 (0.7463 - 0.7471)

Side clearance Standard 0.200 - 0.352 (0.0079 - 0.0138)

Connecting rod big end diameter grade*2

Grade No. AGrade No. BGrade No. CGrade No. DGrade No. EGrade No. FGrade No. GGrade No. HGrade No. JGrade No. KGrade No. LGrade No. MGrade No. N

43.000 - 43.001 (1.6929 - 1.6929)43.001 - 43.002 (1.6929 - 1.6930)43.002 - 43.003 (1.6930 - 1.6930)43.003 - 43.004 (1 6930 - 1.6931)43.004 - 43.005 (1.6931 - 1.6931)43.005 - 43.006 (1.6931 - 1.6931)43.006 - 43.007 (1.6931 - 1.6932)43.007 - 43.008 (1.6932 - 1.6932)43.008 - 43.009 (1.6932 - 1.6933)43.009 - 43.010 (1.6933 - 1.6933)43.010 - 43.011 (1.6933 - 1.6933)43.011 - 43.012 (1.6933 - 1.6934)43.012 - 43.013 (1.6934 - 1.6934)

Center distance “r” 41.68 - 41.76 (1.6409 - 1.6440)

Out-of-round Limit 0.003 (0.0001)

Taper Limit 0.004 (0.0002)

Runout [TIR*1] Limit 0.10 (0.0039)

Crankshaft end playStandard 0.098 - 0.260 (0.0039 - 0.0102)

Limit 0.35 (0.0138)

SEM645PBIC3459J




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*1: Total indicator reading*2 : Always check with the Parts Department for the latest parts information.

Main Bearing INFOID:0000000007575650

MAIN BEARING

Crankshaft pin journal diameter grade.*2 “Dp”

Grade No. AGrade No. BGrade No. CGrade No. DGrade No. EGrade No. FGrade No. GGrade No. HGrade No. JGrade No. KGrade No. LGrade No. MGrade No. NGrade No. PGrade No. RGrade No. SGrade No. TGrade No. U

39.971 - 39.970 (1.5737 - 1.5736)39.970 - 39.969 (1.5736 - 1.5736)39.969 - 39.968 (1.5736 - 1.5735)39.968 - 39.967 (1.5735 - 1.5735)39.967 - 39.966 (1.5735 - 1.5735)39.966 - 39.965 (1.5735 - 1.5734)39.965 - 39.964 (1.5734 - 1.5734)39.964 - 39.963 (1.5734 - 1.5733)39.963 - 39.962 (1.5733 - 1.5733)39.962 - 39.961 (1.5733 - 1.5733)39.961 - 39.960 (1.5733 - 1.5732)39.960 - 39.959 (1.5732 - 1.5732)39.959 - 39.958 (1.5732 - 1.5731)39.958 - 39.957 (1.5731 - 1.5731)39.957 - 39.956 (1.5731 - 1.5731)39.956 - 39.955 (1.5731 - 1.5730)39.955 - 39.954 (1.5730 - 1.5730)39.954 - 39.953 (1.5730 - 1.5729)

Crankshaft main journal diameter grade.*2 “Dm”

Grade No. AGrade No. BGrade No. CGrade No. DGrade No. EGrade No. FGrade No. GGrade No. HGrade No. JGrade No. KGrade No. LGrade No. MGrade No. NGrade No. PGrade No. RGrade No. SGrade No. TGrade No. UGrade No. VGrade No. W

47.979 - 47.978 (1.8889 - 1.8889)47.978 - 47.977 (1.8889 - 1.8889)47.977 - 47.976 (1.8889 - 1.8888)47.976 - 47.975 (1.8888 - 1.8888)47.975 - 47.974 (1.8888 - 1.8887)47.974 - 47.973 (1.8887 - 1.8887)47.973 - 47.972 (1.8887 - 1.8887)47.972 - 47.971 (1.8887 - 1.8886)47.971 - 47.970 (1.8886 - 1.8886)47.970 - 47.969 (1.8886 - 1.8885)47.969 - 47.968 (1.8885 - 1.8885)47.968 - 47.967 (1.8885 - 1.8885)47.967 - 47.966 (1.8885 - 1.8884)47.966 - 47.965 (1.8884 - 1.8884)47.995 - 47.964 (1.8884 - 1.8883)47.994 - 47.963 (1.8883 - 1.8883)47.963 - 47.962 (1.8883 - 1.8883)47.962 - 47.961 (1.8883 - 1.8882)47.961 - 47.960 (1.8882 - 1.8882)47.960 - 47.959 (1.8882 - 1.8881)



EM-126


Unit: mm (in)

UndersizeUnit: mm (in)

Bearing Oil ClearanceUnit: mm (in)

Connecting Rod Bearing INFOID:0000000007575651

CONNECTING ROD BEARINGUnit: mm (in)

Grade number Thickness Identification color Remarks

0 1.996 - 1.999 (0.0785 - 0.0787) Black

Grade and color are the same for upper and lower bearings.

1 1.999 - 2.002 (0.0787 - 0.0788) Brown

2 2.002 - 2.005 (0.0788 - 0.0789) Green

3 2.005 - 2.008 (0.0789 - 0.0790) Yellow

4 2.008 - 2.011 (0.0790 - 0.0791) Blue

5 2.011 - 2.014 (0.0791 - 0.0792) Pink

01UPR 1.996 - 1.999 (0.0785 - 0.0787) Black

Grade and color are different for upper and lower bearings.

LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown

12UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown

LWR 2.002 - 2.005 (0.0788 - 0.0789) Green

23UPR 2.002 - 2.005 (0.0788 - 0.0789) Green

LWR 2.005 - 2.008 (0.0789 - 0.0790) Yellow

34UPR 2.005 - 2.008 (0.0789 - 0.0790) Yellow

LWR 2.008 - 2.011 (0.0790 - 0.0791) Blue

45UPR 2.008 - 2.011 (0.0790 - 0.0791) Blue

LWR 2.011 - 2.014 (0.0791 - 0.0792) Pink

SEM685D

Items Thickness Main journal diameter

US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.

Main bearing oil clearance Standard 0.024 - 0.034 (0.0009 - 0.0013)

Grade number Thickness Identification color Remarks

1 1.501 - 1.504 (0.0591 - 0.0592) Brown

Grade and color are the same for upper and lower bearings.

2 1.504 - 1.507 (0.0592 - 0.0593) Green

3 1.507 - 1.510 (0.0593 - 0.0594) Yellow

4 1.510 - 1.513 (0.0594 - 0.0596) Blue

5 1.513 - 1.516 (0.0596 - 0.0597) Pink




EM-127


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UndersizeUnit: mm (in)

Bearing Oil ClearanceUnit: mm (in)

12UPR 1.501 - 1.504 (0.0591 - 0.0592) Brown

Grade and color are different between upper and lower bear-ings.

LWR 1.504 - 1.507 (0.0592 - 0.0593) Green

23UPR 1.504 - 1.507 (0.0592 - 0.0593) Green

LWR 1.507 - 1.510 (0.0593 - 0.0594) Yellow

34UPR 1.507 - 1.510 (0.0593 - 0.0594) Yellow

LWR 1.510 - 1.513 (0.0594 - 0.0596) Blue

56UPR 1.513 - 1.516 (0.0596 - 0.0597) Pink

LWR 1.516 - 1.519 (0.0597 - 0.0598) Purple

Items Thickness Crankshaft pin journal diameter

US 0.25 (0.0098) 1.627 - 1.635 (0.0640 - 0.0644) Grind so that bearing clearance is the specified value.

Connecting rod bearing oil clearanceStandard 0.020 - 0.030 (0.0008 - 0.0012)

Limit 0.10 (0.0039)



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